This is a Technical Journal: Washer system layout for identifying leakage points REF NO : ISSUING DEPARTMENT : CAR MARKET : United States and Canada TJ 25153 Technical Service PARTNER : ISSUE DATE : STATUS DATE : 3 US 7510 Volvo Car USA 2016 - 03 - 17 2016 - 03 - 24 FUNC GROUP : FUNC DESC : 3634 Washer Page 1 of 24 Attachment File Name File Size TJ 25153 S60 MY11 - , V60 , S60 , V60CC.pdf 0.8349 MB TJ 25153 S80 MY07 - , V70 MY08 - , XC70 MY08 - . pdf 0.7857 MB TJ 25153 S90 ( 234 ) MY17 - . pdf 1.4623 MB TJ 25153 V90V90CC ( 235236 ) MY17 - . pdf 1.5192 MB TJ 25153 XC90 ( 256 ) MY16 - . pdf 2.1365 MB TJ 25153_XC60 . pdf 0.8801 MB Vehicle Type Eng Struc Week Type Eng Sales Body Gear Steer Model
full bulletin at NHTSA ↗2005 Volvo S40 fuel system problems
moderate 11 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
11
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 11 fuel system complaints filed for the 2005 Volvo S40, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA fuel system complaint has been filed on this vehicle in over 14 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
VOLVO: INFORMATION BEING PROVIDED REGARDING THE REPLACEMENT AND INSTALLATION OF STEEL FUEL TANK ON SOME VEHICLES. MODEL 2005-2010 S40, V50.
full bulletin at NHTSA ↗PUMP ELECTRONIC MODULES (PEM) TO PRIOR APPROVAL.
full bulletin at NHTSA ↗VOLVO: LEAKAGE DETECTION DIAGNOSTICS IMPROVEMENTS TO REMEDY DTC'S. ALL MODELS FROM MODEL YEARS 2003-2008. DIAGNOSTIC MONITOR FOR THE EVAPORATIVE EMISSION SYSTEM SMALL LEAK, HAS USED A SOFTWARE FUNCTION THAT CALCULATES LEAKAGE BASED ON A PRESSURE INFERRED FROM THE CURRENT CONSUMED BY AN ELECTRIC PUMP THAT PUMPS AIR INTO THE FUEL TANK SYSTEM.
full bulletin at NHTSA ↗VOLVO: EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (SALTY WET CONDITIONS) IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report three distinct fuel-system failures in 2005 Volvo S40s. The most common is fuel pressure sensor failure: drivers experience engine stalls at highway speed, power surges during cold start, and check-engine lights. Bosch sensor part numbers 8699448 and 31272730 are cited; one owner's replacement sensor failed again within 7,000 miles. Volvo recall 181 covered identical sensors in 2003-2004 S60/V70 models but excludes the S40, leaving owners responsible for $550+ repairs.
Fuel pump electronic module failure causes similar stalling symptoms, often triggered by corrosion in salt-exposure climates. One TSB mentions relocating the module from the engine compartment to behind the rear seat to prevent water intrusion. NHTSA campaign 08V033000 addresses this, but Volvo denies coverage for many S40 VINs, claiming they were never registered to the recall.
A third issue involves Teflon fuel lines installed under recall R158: the replacement lines leak after only four years, well short of typical service life. Owners report frustration with coverage denials despite matching the failure descriptions in official recalls.
Failure modes owners describe
Fuel Pressure Sensor Failure
Fuel pressure sensor (part numbers 8699448, 31272730, 31272733) develops electrical fault or internal failure, often after corrosion exposure. Volvo recall 181 covered 2003-2004 S60/V70 models with this sensor, but 2005 S40 owners with identical sensors report the same problem without recall coverage.
When: Between 43,000 and 147,000 miles; one case within 7,000 miles of replacement
Symptoms owners cite: Engine stalling without warning while driving at highway speed; Power surge behavior during cold start or after extended idle; Check Engine Light illumination (intermittent or continuous); Misfires; Loss of power assist steering; Dashboard warning lights illuminated
Codes mentioned: P0190 (inferred from fuel pressure sensor diagnostic indication)
Repairs/costs cited: OEM fuel pressure sensor replacement cost approximately $550 at Volvo dealership (2011 labor included); replacement sensor failed again within 2 years and 7,000 miles
Recalls/TSBs owners mention: Volvo recall 181 limited to 2003-2004 S60/V70; VIN-dependent coverage denied for 2005 S40 despite identical sensor and failure mode
Fuel Pump Electronic Module Corrosion and Failure
Fuel pump electronic module (also called fuel control module) corrodes and fails due to moisture intrusion, particularly in salt-exposure climates. Water penetration causes electrical short or complete module failure, resulting in sudden engine stall.
When: 71,000 to 147,000 miles
Symptoms owners cite: Random stalling while driving; Power Service Warning Light illumination; Engine will not start; No warning prior to stall
Repairs/costs cited: Module replacement at independent mechanic; Volvo dealership diagnosis mentioned rusting/corrosion; one complaint notes TSB for relocation of module from engine compartment to behind rear seat to address water intrusion
Recalls/TSBs owners mention: NHTSA campaign 08V033000 (Fuel System, Gasoline: Delivery: Fuel Pump) exists but affected vehicles determined not to include complainant VINs; Volvo denied coverage stating VIN not included in recall scope
Teflon Fuel Line Premature Wear and Leakage
Replacement Teflon fuel line (installed under recall R158 in place of original polyamide line) becomes worn and permeable after approximately four years, leaking fuel during operation.
When: Four years post-replacement under recall R158
Symptoms owners cite: Fuel leakage from fuel line
Repairs/costs cited: Teflon fuel line replacement performed under recall R158; premature failure at four years when typical fuel line service life exceeds this period
Recalls/TSBs owners mention: Recall R158 applied to replace polyamide fuel line with Teflon line; replacement line itself failed prematurely
Synthesized from 11 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
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…
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…
Had fuel system trouble with your 2005 Volvo S40?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Volvo S40?
It's a documented issue but not catastrophic. 11 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 10 complaints that reported odometer mileage, most fuel system failures cluster between 53,500 and 116,740 miles, with the median around 78,000. A quarter of owners report trouble before 53,500; a quarter make it past 116,740. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Volvo/S40.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.