What are the most common Volvo S40 problems?
According to Au7o's analysis of 4,280+ owner reports, the 2004 Volvo S40 has 5 documented issues. The most frequently reported are: PCV System Failure Causing Oil Leaks and Engine Damage, Electronic Throttle Module (ETM) Failure, T5 Turbocharger Failure from Oil Starvation. Of these, 4 are rated critical and should be addressed promptly.
Is the Volvo S40 reliable?
The 2004 Volvo S40 has 5 known issues documented across 4,280+ owner reports. 4 issues are rated critical: PCV System Failure Causing Oil Leaks and Engine Damage and Electronic Throttle Module (ETM) Failure and T5 Turbocharger Failure from Oil Starvation and Electric Power Steering Pump Failure. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Volvo S40 problems?
Repair costs for known Volvo S40 issues range from $100 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, PCV System Failure Causing Oil Leaks and Engine Damage, typically costs $300-$1,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2004-2012 Volvo S40 PCV System Failure Causing Oil Leaks and Engine Damage?
The PCV (positive crankcase ventilation) system on the S40/V50 2.5L T5 engine is a well-known failure point. The system uses a complex oil separator and breather box that clogs with oil sludge, causing excessive crankcase pressure. This pressure forces oil past every seal in the… Repairs typically run $300-$1,500. Severity: high.
What is the 2004-2011 Volvo S40 Electronic Throttle Module (ETM) Failure?
The electronic throttle module (ETM) on S40/V50 models with the 2.4L non-turbo (B5244S) and early T5 engines fails due to internal solder joint cracking from thermal cycling. The ETM controls the throttle blade electronically, and when it fails, the engine enters limp mode with s… Repairs typically run $250-$800. Severity: high.
What is the 2004-2012 Volvo S40 T5 Turbocharger Failure from Oil Starvation?
The Mitsubishi TD04L-14T turbocharger on the S40/V50 T5 fails prematurely when oil supply is restricted. The most common cause is a clogged PCV system (which back-pressures the oil return line), deteriorated oil feed line banjo bolt screens, or extended oil change intervals allow… Repairs typically run $1,200-$3,500. Severity: high.
What is the 2004-2011 Volvo S40 Electric Power Steering Pump Failure?
The electrically driven power steering pump fails or develops a loud whine. Unlike traditional belt-driven pumps, the S40 uses an electric motor to drive the hydraulic pump. The motor burns out or the pump internals wear, losing pressure. Repairs typically run $400-$1,000. Severity: high.
What is the 2004-2011 Volvo S40 Upper Engine/Transmission Mount Failure?
The upper engine torque mount breaks or collapses, causing a heavy vibration at idle and a lurch when shifting between drive and reverse. The mount is visible from above and can be checked by looking for cracks or separation in the rubber. Repairs typically run $100-$350. Severity: medium.
