2005 Volvo S40 Fuel system Problems

The contact's wife owns a 2005 Volvo S40. The contact stated the vehicle was difficult to start for several days. Eventually, the failure progressed and the vehicle was not able to start. The check engine warning light was illuminated. The vehicle was repaired by the contact, a previous Volvo technician. The contact stated the failure was due to the pump electrical module being located out of the vehicle. The contact spoke with the dealer. The contact referenced The manufacturer was made aware of the failure. The approximate failure mileage was 170,000.

NHTSA ID

11578530

Incident

Feb 21, 2024

Mileage

170,000 mi

TL* THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT WHILE DRIVING AT AN UNDISCLOSED SPEED, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP ELECTRONIC MODULE HAD FAILED DUE TO RUSTING AND CORROSION. THE FUEL PUMP ELECTRONIC MODULE WAS REPLACED AND THE FAILURE WAS REMEDIED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER 08V033000 (FUEL SYSTEM, GASOLINE). THE CONTACT STATED THAT THE VEHICLE HAD EXPERIENCED THE FAILURE LISTED IN THE RECALL. ADDITIONALLY, THE VEHICLE WAS ORIGINALLY SOLD IN THE STATE OF CALIFORNIA AND HAD BEEN DRIVEN IN THE STATE OF MICHIGAN THE PAST 6 YEARS. THE FAILURE MILEAGE WAS 147,000.

NHTSA ID

11403711

Incident

Mar 15, 2021

Mileage

147,000 mi

I WAS TOLD BY SHOP THAT WORK ON MY CAR THAT WERE A RECALL ON THE PVC VAUL ON THE 2005 VOLV S40 2.4. *TR

NHTSA ID

11329021

Incident

Jun 14, 2020

Mileage

84,000 mi

MY VEHICLE SHUTS OFF WHILE IM DRIVING IT. I TOOK IT TO A MECHANIC 3 TIMES AND WAS ADVISED ITS AN ISSUE WITH THE FUEL PUMP. I WAS ALSO ADVISED THIS IS AN KNOWN ISSUE WITH THIS PARTICULAR VEHICLE AND WAS PROVIDED A NHTSA CAMPAIGN ID # 08V033000. *TR

NHTSA ID

11327540

Incident

Jun 4, 2020

Mileage

168,505 mi

THE CAR STARTS MISSING THEN STALLS OUT AFTER ABOUT 30MILES OF DRIVING IT STALLED IN THE MIDDLE OF CROSSING A 4 LANE AND WAS ABOUT HIT.IT IS THE PEM THEY HAD RECALLS ON THEM BUT NOT MY CAR FOR SOME REASON

NHTSA ID

11111793

Incident

May 10, 2018

Mileage

205,000 mi

EVERY TIME I DRIVE THE CAR IT MISSES A LITTLE THEN IT JUST SHUTS DOWN LIKE IT'S NOT GETTING ANY FUEL THE CAR DON'T DIE JUST WON'T PULL OUT I TRIED TO CROSS A 4 LANE AND IT STALLED IN THE FIRST LANE AND I ABOUT GOT HIT IN THE SIDE IT ALSO DID IT ON THE INTERSTATE.IT IS VERY DANGEROUS I WAS TOLD IT'S THE ELECTRONIC FUEL MODULE,OR PEN AND WAS TOLD THERE WAS A RECALL ON THAT PART ALL OVER THE INTERNET BUT VOLVO SAID THERE WASN'T WHICH I DON'T BELIEVE WHY WOULD THE INTERNET SAY THERE WAS ON LIKE 5OR NOTRE WEBSITES

NHTSA ID

11111408

Incident

May 12, 2018

Mileage

200,011 mi

FUEL PUMP CONTROL MODULE (PEM) FAILS DURING WET CONDITIONS. CAR WILL CRANK LIKE NORMAL BUT WILL NOT START. LET CAR DRY OUT FOR A FEW DAYS AND THEN THE CAR WILL RUN NORMAL AGAIN.

NHTSA ID

10985089

Incident

May 12, 2017

Mileage

156,000 mi

TAKATA RECALL. I HAD ENGINE STUTTERING AT HIGH SPEED. MY FUEL PRESSURE SENSOR FAILED AND WAS REPLACED. I QUESTION WHY IT IS NOT COVERED UNDER THE NHTSA CAMPAIGN I.D. # 07V226000 WHICH IS FOR THE SAME PART IN THE SAME ENGINE BUT IN 2004 S60 MODELS.

NHTSA ID

10955043

Incident

Feb 15, 2017

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2005 VOLVO S40. WHILE DRIVING VARIOUS SPEEDS ON SEVERAL OCCASIONS, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP ELECTRONIC MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 08V033000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.

NHTSA ID

10816978

Incident

Jul 2, 2014

Mileage

40,000 mi

CAR STALLS WITH OUT WARNING WHEN TRAVEL AT SPEEDS OF 0-65 MPH VERY DANGEROUS!! THERE ARE RECALLS RE: FUEL PRESSURE SENSORS FOR NEARLY ALL VOLVO MAKES EXCEPT THE S40 2005 THIS PART IS TRULY A DEFECTIVE ITEM AND NEEDS TO BE RECALLED BEFORE A DEATH OCCURS ON THE HIGHWAY!! I THOUGHT VOLVO WAS A SAFE RELIABLE CAR BUT I CAN HONESTLY SAY THIS CAR IS THE BIGGEST PIECE OF JUNK I HAVE EVER SPENT A LOT OF MONEY ON. THE TIRES BLEW OUT ON THE SIDES WHICH ALSO PUT ME IN DANGER THE INTERIOR HEADLINER FELL OFF AS WELL AS ALL OTHER MATERIAL ON THE DOORS ALL LEATHER IS LOOSE GEAR SHIFTER COVER FELL APART. GAS CAP BROKE GAS BUILDS TOO MUCH PRESSURE LOOSENING THE GAS CAP FREQUENTLY THESE ARE JUST SOME OF THE ISSUES I HAVE. VERY DISAPPOINTED IN THIS VEHICLE I KEEP MY CAR IN THE GARAGE. ONLY DRIVE TO AND FROM GROCERY SHOPPING AND DR APPTS PLEASE CONSIDER RECALLS ON THE IMPORTANT PARTS OF THE VEHICLE THAT CAN SAVE LIVES! *JS

NHTSA ID

10592271

Incident

Dec 6, 2012

Mileage

20,500 mi

MY CAR WAS MAKING A PUMPING NOISE FROM THE REAR OF THE CAR AND THE CHECK ENGINE LIGHT WOULD COME ON. I TOOK IT TO A LOCAL MECHANIC AND THEY INFORMED ME OF THE PEM RECALL/EXTENDED WARRANTY. I TOOK THE CAR TO THE VOLVO DEALERSHIP TO HAVE REPAIRED AND THEY SAID THE PEM WAS NOT THE PROBLEM AND THAT IT WAS A FUEL PRESSURE SENSOR AND POSSIBLY THE FUEL PUMP ITSELF. I DECLINED THE REPAIR AND EXACTLY 2 WEEKS LATER THE CAR FAILED TO START. I HAD IT TOWED TO MY LOCAL MECHANIC SINCE I LIVE 70 MILES FROM THE VOLVO DEALERSHIP. MY MECHANIC REPLACED AND MOVED THE PEM TO A NEW LOCATION, WHICH WAS EXACTLY WHAT THE RECALL/EXTENDED WARRANTY WAS FOR! THE DEALERSHIP GAVE ME A FORM FOR REIMBURSEMENT FROM VOLVO, BUT VOLVO REFUSED TO PAY THE $634 THAT I PAID FOR THE REPAIR. THEY FIRST TRIED TO SAY IT WAS NOT A "GENUINE VOLVO PART" BUT I VERIFIED IT WAS. THEN THEY SAID SINCE I DECLINED THE REPAIR FOR THE FUEL PRESSURE SENSOR, THEY COULD NOT PAY! THE REIMBURSEMENT FORM IS FOR THE PEM AND HAS NOTHING TO DO WITH THE FUEL PRESSURE SENSOR. SO THIS PEM BECAME FAULTY IN A 2 WEEK PERIOD? I THINK NOT! OBVIOUSLY VOLVO DOES NOT STAND BEHIND THEIR CARS AND I FEEL LIKE THEY LIED TO ME. *TR

NHTSA ID

10532656

Incident

Jun 11, 2013

Mileage

93,000 mi

I HAVE RESEARCHED VOLVO FORUMS AND FOUND THAT VOLVO COMPLETED RECALL #181 FOR A FUEL PRESSURE SENSOR. (HTTP://SS.OTHERON.COM/RKELLY/VIDEO/R181+RETAILER+LETTER+-+FINAL.PDF) WHILE I DON'T OWN A VEHICLE INCLUDED IN VOLVO RECALL 181, I DO OWN A VOLVO WHICH SHARES THE SAME FUEL PRESSURE SENSOR. HERE IS THE BACKGROUND: I DRIVE A 2005 VOLVO S40, T5 AWD. I AM THE ONLY PERSON WHOM HAS EVER OWNED THIS CAR. IN SEPTEMBER 2011 MY FUEL PRESSURE SENSOR FAILED AND I WAS CHARGED APPROXIMATELY $550 AT THE DEALERSHIP TO HAVE IT REPLACED. IT FAILED WHILE I WAS DRIVING ON THE HIGHWAY. I HAD ALSO EXPERIENCED POWER-SURGE TYPE BEHAVIORS DURING START-UP, AFTER THE CAR HAD SET OVERNIGHT OR DURING MY WORKDAY. YESTERDAY, WITH THE KIDS IN THE CAR, I WAS DRIVING ALONG ABOUT 60MPH AND ALL OF A SUDDEN IS WAS LIKE MY CAR HAD STALLED OUT. THE BRAKES WORKED AND TURN SIGNALS WORKED. HOWEVER, THE STEERING HAD TIGHTENED UP. ALL OF THE LIGHTS ON THE DASHBOARD WERE LIT. I COASTED TO THE FAR RIGHT LANE AND TURNED ON MY CAUTION LIGHTS, STILL BEING IN THE ACTUAL ROAD. I TURNED THE KEY OFF AND THEN RESTARTED THE CAR. THE CAR STARTED OK. AS SOON AS I ARRIVED HOME IT HAPPENED AGAIN; THIS WAS NOT EVEN 5 MILES AND 15 MINUTES LATER. THE CURRENT FUEL PRESSURE SENSOR PART NUMBER SHOWS BOSCH PART- 31272730; WHICH, AGAIN, WAS NEW AS OF 2011. I'M CONCERNED THAT THE REPLACEMENT PART IS NOW FAILING- ALMOST 2 YEARS LATER AND LESS THAN 7,000 MILES LATER! RECENTLY I HAVE ALSO FOUND THE ISSUES WITH THE POWER-SURGE DURING START UP HAVE BEGAN RECURRING. UNTIL RESEARCHING THE ISSUE I WAS UNAWARE THERE WAS A RELATION BETWEEN THE POWER-SURGE AND FUEL PRESSURE SENSOR. I HAVE AN APPOINTMENT ON MONDAY TO DROP OFF MY CAR AT VOLVO. AT THIS POINT I DON'T HAVE CONFIDENCE THAT THE ROOT CAUSE AND COMPLETE SCOPE HAVE BEEN IDENTIFIED IN VOLVO RECALL #181 OR THAT REPLACING THIS PART WILL CORRECT THE SAFETY ISSUE. *TR

NHTSA ID

10522417

Incident

Jun 28, 2013

Mileage

116,740 mi

THE VEHICLE EXHIBITED STALLING AND MISFIRES THE FIRST TIME AT 65 MPH. THE CHECK ENGINE LIGHT (CEL) CAME ON AND THE DIAGNOSTIC INDICATION WAS THAT FUEL PRESSURE SENSOR NEEDED REPLACED. IT CONTINUED WITH STALL AND MISFIRE AT INTERMITTENT TIMES WITH THE CEL STAYING ON AND OFF INTERMITTENTLY. I BOUGHT A FUEL PRESSURE SENSOR AND REPLACED THE ORIGINAL, WHICH HAS REMEDIED THE PROBLEM. WHEN I REPLACED THE FUEL PRESSURE SENSOR, I EXAMINED THE ORIGINAL PART AND NOTED THAT IT HAD A PART NUMBER OF 8699448 INSTEAD OF 31272733 LIKE THE REPLACEMENT PART. PUTTING IN FUEL PRESSURE SENSOR 8699448 ON THE INTERNET, I QUICKLY FOUND VOLVO RECALL 181 WHICH COVERS THIS PART FOR VOLVO 2003 - 2004 S60/V70 CARS (48,000 PLUS). MY MOTOR IS A SLIGHT VARIANT OF THE MOTORS USED AND NOT INCLUDED. IT IS OBVIOUS THAT THE MAJOR PART OF CONSIDERATION IS THE FUEL PRESSURE SENSOR 8699448 BUT VOLVO DID NOT SEE THEIR WAY TO INCLUDE ALL MOTORS USING THIS PART AND THE DANGER IS NO DIFFERENT FOR THE S40 THAN THE S60/V70. THE INTERNET SHOWS MANY OTHER EXAMPLES OF THIS FAILURE WITHIN 2005 S40S. THIS IS PROBABLY THE TIP OF THE ICEBERG WITH MANY MORE TO FOLLOW AND POSSIBLE POTENTIAL DANGEROUS ACCIDENTS IMPENDING. ALL INFORMATION I RELAYED IN THIS COMPLAINT HAS BEEN TOLD TO MY LOCAL VOLVO DEALER AND VOLVO CUSTOMER SERVICE (NATIONAL). *TR

NHTSA ID

10440254

Incident

Mar 1, 2011

Mileage

83,000 mi

TL* THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT THE VEHICLE WOULD STALLS RANDOMLY WITH THE ILLUMINATION OF THE POWER SERVICE WARNING LIGHT. THE CONTACT TOOK THE VEHICLE TO A MECHANIC AND WAS TOLD THAT THE PUMP ELECTRONIC MODULE WAS FAILING AND THAT THERE WAS A RECALL FOR THE FAILURE (NHTSA CAMPAIGN ID NUMBER: 08V033000-FUEL SYSTEM GASOLINE: DELIVERY: FUEL PUMP). THE CONTACT SPOKE WITH THE MANUFACTURER AND WAS TOLD THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE FAILURE MILEAGE WAS 71,000.

NHTSA ID

10425573

Incident

May 10, 2011

Mileage

71,000 mi

A 2005 VOLVO S40 T5 MODEL HAS REPEATING FUEL LINE LEAKAGE. THE CAR WAS SERVICED TO REPLACE THE ORIGINAL POLYAMIDE FUEL LINE TO A TEFLON FUEL LINE IN LINE WITH RECALL R158. AFTER FOUR YEARS THE TEFLON FUEL LINE WAS BECOME WORN AND FUEL HAS BEGUN TO FLOW FROM THE LINE. THE AVERAGE FUEL LINE LIFE IS WELL BEYOND FOUR YEARS. THERE IS AN UNDERLYING ISSUE WITH THE FUEL LINE WITH THE 2005 VOLVO S40 T5. *TR

NHTSA ID

10380223

Incident

Jan 20, 2011

Mileage

75,000 mi

TL*THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT ILLUMINATED AND THE VEHICLE STALLED WHILE SHE WAS DRIVING. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE IT WAS REPAIRED ACCORDING TO RECALL 08V033000 (FUEL SYSTEM, GASOLINE: DELIVERY:FUEL PUMP) BUT THE CONTACT STILL EXPERIENCED THE SAME FAILURE AFTER THE REPAIR. THE DEALER ALSO INFORMED HER THAT SHE NEEDED TO HAVE A FUEL PUMP SENSOR NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED AGAIN. THE MANUFACTURER HAD NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS APPROXIMATELY 69,000. THE FAILURE MILEAGE WAS APPROXIMATELY 68,000. UPDATED 03/15/11*LJ ALSO, THERE WAS AN INTERNAL FAULT WITH THE IGNITION WHICH CAUSED THE VEHICLE TO SHUT DOWN. UPDATED 04/28/11

NHTSA ID

10365081

Incident

Oct 20, 2010

Mileage

68,000 mi

PURCHASED A VOLVO OVERSEAS IN 2005 AND IT RECENTLY BROKE DOWN LAST WEEK IN THE MIDDLE OF AN INTERSECTION. I HAD IT TOWED TO THE VOLVO DEALER IN FORT WALTON BEACH AND THEY TOLD ME MY PART WAS FAULTY AND WILL HAVE IT RUNNING BY THE NEXT DAY. I CALLED MY WARRANTY COMPANY AND THEY TOLD ME THAT PART HAD BEEN RECALLED AND VOLVO SHOULD PAY FOR IT BUT THEY DENIED THERE WAS A RECALL AND CALLED IT AN EXTENDED WARRANTY. MY WARRANTY COMPANY AMERICAN GUARDIAN SENT A 3RP PARTY MECHANIC TO VOLVO AND VERIFIED IT WAS CORRODED. THE RECALL IS ALL OVER THE WEBS/INCLUDING YOURS NHTSA CAMPAIGN ID #08V033000 SO I CALLED VOLVO AND THEY SAY THERE IS NO RECALL. THE PART AND LABOR WAS $800.00. MY VIN WASN'T LOADED IN THE US SYSTEM UNTIL THIS WEEK. CURRENTLY THE VOLVO DEALER REPLACE THE PART AND MOVED IT TO A DIFFERENT LOCATION AND SAYS IT CAN'T COVER IT UNLESS VOLVO PUT THAT SPECIFIC VIN NUMBER AND LOAD IT AGAINST IT (EXTENDED WARRANTY) BUT HOW IF THERE IS NO RECALL. NEITHER VOLVO OR THE WARRANTY COMPANY WILL PAY FOR THE PART. IF ITS AN OFFICIAL RECALL AND IT HAPPENED JUST LIKE THE DESCRIPTION ON THE RECALL STATES THEY SHOULD BE OBLIGATED TO COVER IT. ITS ONLY GOT 53000 MILES ON IT WHICH IS 3000 OVER THE MANUFACTURE WARRANTY. I FEEL VOLVO NEEDS TO ADD MY VIN TO THE LIST BECAUSE OBVIOUSLY ITS A PROBLEM TO MINE ALSO. I HAVE REFUSED TO PICK UP THE CAR THE LAST WEEK UNTIL I HEARD BACK FORM VOLVO BUT THEY SAID THERE IS NOTHING THEY CAN DO AND I HAVE TO PAY FOR IT. *TR

NHTSA ID

10265614

Incident

Apr 10, 2009

Mileage

53,500 mi

VOLVO S40 YEAR 2004.5 PROBLEMS WITH ENGINE START AND ENGINE CHECK LIGHT COMING ON DUE TO POSSIBLE PROBLEM WITH FUEL PUMP ELECTRONICS. RECALLS ARE ONLY IMPACTING CERTAIN U.S. STATES TO HAVE THE PART REPLACED. WHAT ABOUT RECALLS FOR OWNERS RESIDING OVERSEAS UNDER GOVERNMENT ORDERS? *TR

NHTSA ID

10217317

Incident

Jan 4, 2008

Mileage

15,000 mi

TL*THE CONTACT OWNS A 2005 VOLVO S40. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 08V033000 (FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP). THE CONTACT WAS CONCERNED OF A FAILURE OCCURRING SINCE THE STATE OF KENTUCKY USES SALT. THERE HAD BEEN NO FAILURE TO DATE. THE CURRENT MILEAGE WAS 43,000. UPDATED 02-19-08 *BF UPDATED 02/19/08 *TR

NHTSA ID

10216892

Incident

Feb 4, 2008

THE FUEL CONTROL MODULE FAILED, CAUSING AN IMMEDIATE STALL. THERE IS A TSB CONCERNING THE PLACEMENT OF THIS MODULE. IT IS TO BE MOVED FROM THE ENGINE COMPARTMENT TO BEHIND THE BACK SEAT. WATER GOT INTO THE MODULE CAUSING IT TO MELT DOWN!!! *TR

NHTSA ID

10214096

Incident

Jan 6, 2008

Mileage

78,000 mi