The 2005 Volvo S40 has two recalls, the more serious affecting T5 turbo models: a fuel line tube near the turbocharger and exhaust manifold can degrade from heat, leak fuel, and cause a fire.
The second recall applies to vehicles registered in certain northern and mid-Atlantic states where road salt exposure can corrode the fuel pump over time. A corroded pump can trigger the check engine light, cause the engine to stall while driving, or prevent the vehicle from starting altogether.
At a glance
What can fail
The fuel pump electronic module can corrode from repeated exposure to salty-wet conditions, sending faulty signals that reduce or stop fuel pressure to the engine.
What the fix does
The dealer will replace the fuel pump electronic module and install it in a new location to prevent corrosion.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The plastic fuel line near the turbo engine's hot exhaust area can degrade from extreme heat, potentially causing fuel leaks.
What the fix does
Dealers will replace the fuel line with a heat-resistant Teflon line at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
