2004 Volvo S40 Problems, Complaints & Recalls

Problem: Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.

Risk: An overheated battery could lead to a fire.

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 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.

Problem: 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.

Risk: 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.

Fix: 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.

Problem: 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.

Risk: This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.

Fix: 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.

Problem: On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.

Risk: 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.

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.

Problem: On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.

Risk: Fuel leakage in the presence of an ignition source could result in a fire.

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.

Problem: 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.

Risk: This does not meet the requirements of the standard.

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 to the owner. Owner notification began on december 19, 2003. Owners should contact volvo at 1-800-458-1552.