Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Volvo S40 owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
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.
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
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.
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.
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.
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
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. …
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. …
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. …
Related recalls
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, wisconsin, and the district of columbia, reoccurring,…
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
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.
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.
Fuel System complaints in other S40 years
Frequently asked questions
How common are fuel system problems on the 2005 Volvo S40?
NHTSA has 20 complaints about the fuel & propulsion system of the 2005 Volvo S40, 29% of the model year's 69 complaints. The component named most often is delivery › fuel pump (5 mentions).
Is there a recall for 2005 Volvo S40 fuel system problems?
Yes — NHTSA recall 08V-033 (fuel pump, Jan 28, 2008); NHTSA recall 06V-137 (fuel system, gasoline, Apr 24, 2006). Recall repairs are free at authorized dealers.
At what mileage do 2005 Volvo S40 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 84,000 miles, and 11% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.