This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.
full bulletin at NHTSA ↗2006 Volvo S40 engine problems
severe 10 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
10
Recalls
0
Avg fix
$3,100
1injury
When does it fail?
Of the 10 engine complaints filed for the 2006 Volvo S40, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 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 engine complaint has been filed on this vehicle in over 10 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 engine 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.
Engine Control Module (EMS) Software (MSW) Information â August 2022; Improvement List (Change Log) - US21+OBD22 (13L VGT, TC) And US17+OBD22 (11L) Emissions
full bulletin at NHTSA ↗This is a Technical Journal: Oil in cooling system. New cleaning method developed.
full bulletin at NHTSA ↗This is a Technical Journal: Oil in cooling system. New cleaning method developed.
full bulletin at NHTSA ↗This is a Technical Journal: Oil in cooling system. New cleaning method developed.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 Volvo S40 engine complaints center on three main problem areas. First, the oil filter housing breathing hose deteriorates and rots, allowing pieces to break off during operation. When this happens, oil buildup and vacuum issues develop inside the housing, triggering check engine lights and causing both oil and air leaks. One owner questioned why this vehicle wasn't recalled when others with identical hose problems were.
Second, the engine stalls unexpectedly while driving—at highway speeds, in rush hour traffic, and shortly after startup. In one case, the engine lost all power while on a highway. Stalling happens intermittently and recurs even after restart. Dealers and independent mechanics have repeatedly failed to diagnose these stalls.
Third, the EGR (oil trap housing) made of brittle black plastic cracks and breaks, sucking air into the ventilation system and triggering emission codes. Owners suspect the resulting pressure buildup may damage oil cam seals prematurely. Finally, some owners experienced multiple system failures—brake failure warnings, anti-skid faults, reduced engine performance, and repeated check engine lights—with dealership repairs failing to stick.
Same Volvo S40 engine reports on nearby years: 2005
Failure modes owners describe
Oil filter housing and breathing hose deterioration
The corrugated breathing hose connected to the oil filter housing becomes severely rotted and breaks apart during operation. The hose failure allows oil buildup and vacuum issues inside the housing, leading to gunk accumulation, oil leaks, and air leaks. One owner noted this mirrors issues in recalled vehicles but questioned why their S40 was not included in a recall.
When: Not specified in narratives
Symptoms owners cite: Corrugated breathing hose rotted and broken; Oil filter housing buildup and deterioration; Check engine light illuminated; Oil and air leaks
Codes mentioned: Check engine light
Repairs/costs cited: Owner replaced oil filter housing due to damage; specific repair costs not mentioned
Recalls/TSBs owners mention: Owner references other vehicles recalled for the same hose rotting issue but states this S40 was not recalled
Engine stalling at speed
Engine stalls suddenly while driving at highway speeds without warning. Stalling occurs intermittently and recurs even after restart. Check engine light illuminates. Dealers and independent mechanics were unable to diagnose or repair the problem.
When: 78,000 miles and 114,000 miles in separate complaints; occurs shortly after vehicle startup in some cases
Symptoms owners cite: Engine stalls without warning; Check engine light illuminates; Intermittent stalling recurrence; Vehicle can restart after several attempts
Codes mentioned: Check engine light
Repairs/costs cited: No repairs completed; independent mechanic unable to diagnose; dealer unable to determine failure
Recalls/TSBs owners mention: Manufacturer was not made aware of these failures in some cases
EGR/oil trap housing brittle plastic failure
The EGR (oil trap housing) plastic body becomes brittle and breaks, allowing unwanted air intake and improper ventilation. This triggers emission codes on the dash. The owner notes the plastic housing is defective by design and suspects the pressure buildup may contribute to premature oil cam seal failure.
When: Not specified in narratives
Symptoms owners cite: Broken EGR/oil trap housing tubing; Air intake into ventilation system; Emission code triggered on dash; Improper engine ventilation
Codes mentioned: Emission code
Repairs/costs cited: Not specified in narratives; owner reports experiencing premature oil cam seal failure which they attribute to pressure buildup
Multiple system failures with limp mode and repeated check engine light
Vehicle displays multiple fault messages including brake failure, anti-skid system failure, and reduced engine performance. Speed is limited to 15 mph. Dealer replaced computer message module but problem recurred after 500 miles. In separate complaint, check engine light came on repeatedly; vehicle remained at dealership for three weeks without diagnosis.
When: 1.5 years old (second complaint); third occurrence of check engine light in third complaint
Symptoms owners cite: Brake failure warning message; Anti-skid system failure warning; Reduced engine performance message; Speed limited to 15 mph; Check engine light repeating; Engine cannot restart in some instances
Codes mentioned: Brake failure code, Anti-skid system failure code, Reduced engine performance code, Check engine light
Repairs/costs cited: Dealer replaced computer message module; problem recurred 500 miles later; dealership unable to diagnose recurring problem after three weeks
Complete engine power loss while driving
Engine power shuts off completely while driving on highway during rush hour traffic, forcing driver to coast vehicle to safety.
When: Not specified in narratives
Symptoms owners cite: Complete loss of engine power; No warning before shutdown
Synthesized from 10 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
Tl* the contact owns a 2006 Volvo s40. The contact stated that while driving at 65 MPH, the engine stalled while the check engine warning light illuminated. The vehicle was able to restart. The vehicle was taken to a dealer where the failure was not determined. The vehicle was not repaired. The manufacturer was not aware of the failure and the VIN was not included in NHTSA campaign number:…
Dt:the contact stated this was the third time that the check engine light came on. The vehicle has been at the dealership for three weeks, and they did not know what the problem with vehicle was. The corporate office contacted her today and told her that as soon as she found out something she would call her back. *ak
When I signed a purchase order on 5/10/08, the odometer disclosure statement was 6225 miles. Jackson Volvo service at hilo did not give me the copy of odometer disclosure statement. It was delivered on 5/12/2008. Then the odometer disclosure statement showed 106,225 miles. The a/c also became very polluted. *tr
My 1 1/2 years old Volvo s40 did this twice, shortly after starting it and moving it for a couple of miles. It displayed the message "brake failure stop car safely", "anti-skid system failure", "reduced engine performance". The car could not go more than 15 MPH. After parking it, I could not restart the engine and the messages kept repeating in random order. The first time that I took it to…
Had engine trouble with your 2006 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 engine problem on the 2006 Volvo S40?
It's a meaningful issue. 10 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 8 complaints that reported odometer mileage, most engine failures cluster between 78,000 and 114,000 miles, with the median around 95,000. A quarter of owners report trouble before 78,000; a quarter make it past 114,000. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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/2006/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.