Volvo S40 2002

Model S40 made in 2002 by Volvo got 39 consumer complains there is 1 recall as well as 9 service bulletins. Consumer complaints with reference, among others things, to air bags, communications and electrical system. Technical service bulletines regarding air bags, electrical system and engine and engine cooling. There was one recall concerning equipment . The car has one 1.9 turbo engine.

Model 2002

Engine [L]CylindersTransmissionDriveEstimate MPG (city/highway/combined)Unadjusted MPG (city/highway/combined)FuelFuel costClassRelease date
1.9 Turbo 4Lockup/automatic, 5 gearsF22/30/2523.9/37.9/28.6649Premium990COMPACT CARS

Recalls


CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
EQUIPMENT - OTHER - LABELS
03V284000VOLVO CARS OF N.A. LLC.from 09/01/2000 to 01/30/2003V (Vehicle)22040712/19/2003OVSCVOLVO CARS OF N.A. LLC.08/01/200308/07/2003
Defect SummaryCertain passenger cars fail to comply with the requirements of federal motor vehicle safety standard no. 225, child restraint anchorage systems. the second isofix guide was not installed in these vehicles and, in certain cases, the owner's manual isofix information is incorrect.
Consequence SummaryThis does not meet the requirements of the standard.
Corrective SummaryOwners will receive a letter/package consisting of the second isofix guide with installation instructions, and in certain cases, the corrected owner's manual may be provided. if the owner wants to take their vehicle to a volvo dealer for installation of the guide, it will be performed at no charge to the owner. owner notification began on december 19, 2003. owners should contact volvo at 1-800-458-1552.
NotesVolvo recall no. 124.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).

Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
AIR BAGS - SIDE/WINDOW
883307/29/200310003400Moisture in b-pillar side impact sensor. *tt10/17/2003
ELECTRICAL SYSTEM
251507/31/2003251510003441The diagnosis of front and rear oxygen sensors can prove difficult since the operation of the rear sensor can influence the operation of the front sensor. the sensors share common sources of potential faults but also have unique fault sour10/20/2003
ENGINE AND ENGINE COOLING - ENGINE
365805/01/200710022341Immobilizer warning lamp lit or flashing, immo-dtc 321. *kb08/02/2007
POWER TRAIN - AUTOMATIC TRANSMISSION
RTJ-2132407/10/200910032425Volvo: the 5 speed automatic transmission, aw55-50/51, has a bolt on top that anchors the b4 band, which applies 3rd gear. if that bolt is removed, the band will be disengaged and 3rd gear will be inoperative. this includes c70 coupe and03/24/2010
POWER TRAIN - AUTOMATIC TRANSMISSION - CONTROL MODULE (TCM, PCM)
400207/07/200610016434Transmission control module (tcm) upgrades available to correct complaints/symptoms. *tt09/12/2005
SUSPENSION
600708/29/200310016415Front end pulls left or right (camber adjustment) *tt09/12/2005
760101/31/2002630879Experiencing a knocking noise from the front suspension. *tt04/25/2002
TIRES
00601/10/200610019023Winter tire applications. *tt02/09/2006
UNKNOWN OR OTHER
610407/24/200310003398Clunking noise may be heard during gear changes between drive and reverse. *tt10/17/2003

Consumer Complaints


Fail datemilesoccurencesPurchase date
AIR BAGS - FRONTAL
01/11/20031
 The consumer sustained major injuries when the vehicle struck a tree. the seat belt didn't hold him in place and the air bags didn't deploy. *ph *sc *jb
10/12/20025000108/01/2002
 While driving 35 mph the consumer was involved in a frontal collision but the airbags failed to deploy. the manufacturer indicated that the system worked properly. *jb *nlm
COMMUNICATIONS - HORN ASSEMBLY
6109/20/2002
 The horn failed to function properly when horn button was pressed from the left side. the horn did not work at times or excessive force was needed.*ak consumer was involved in a rear end collision in which he tried to use the horn but it didn't work. vehicle was brought in several times but not repaired to working order. *ph *jb
ELECTRICAL SYSTEM
06/06/20091
 Front end suspension isn't right,pulls when driving and there is a knocking items nhtsa 10016415 and 630879. check engine has always been on 10003441. there is a clunking noise when shifting 10003398. there was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for inspection in nc. *tr
06/01/2005480001011/12/2003
 In september of 2004, i began experiencing problems with my volvo s40 sedan. the vehicle would shut off while i was operating it for no apparent reason. i took the vehicle to the dealer twice and then contacted the volvo customer care department following an incident when the vehicle shut off while i was in a very busy intersection in town. i narrowly avoided a very serious crash. they sent a regional technician to the volvo dealer. volvo had the car for an extended period of time and said while they could not determine the problem, they replaced several parts. i experienced no further problems until june of 2005 when the exact problem resurfaced. when i took the car back to the dealer and contacted volvo customer care, they indicated to me that they still could not tell what was wrong with the car and so they would not throw parts at a car. my husband and i are both in law enforcement and know firsthand the devastation of car crashes. we felt so unsafe in the vehicle, that we decided to trade it in july of 2005....a very costly and financially devastating result. (we lost over $4,300) however, i felt too guilty to sell the car to anyone privately. i was so disappointed that volvo refused to deal with this problem and left me no other choices than to drive in a very unsafe car, or face financial devastation. *jb
01/20/2005706/20/2002
 I have had to replace a headlight 3 times and a taillight 2 times, a console light, and the fuse to my cigarette lighter in my 2002 volvo s40; 5 of these things in the last six weeks. the volvo dealership says volvos now ( they didn't specify any particular year of volvos) are blowing headlights so frequently, that the customer reps keep headlight bulbs in their desk drawers and replace them for free. to me, this means either there is a significant problem with the volvo voltage regulators or this particular volvo dealership is putting me off to try keep this repair from being taken care of by my car warranty. i say this because the first time i asked about my lights blowing so frequently, they told me it was because light bulbs tend to blow in cold weather. the second time i asked, they said all volvos were doing that. i looked on your site about safety recalls on volvos and saw nothing about voltage problems. tonight i have also sent an email to volvo.com site so obviously i haven't gotten a response from them. since safety lights (headlight and taillights) are an issue with the problem i'm having with my car and the volvo dealership says it's a common volvo problem, i thought i should pass this by your site to see what you have heard. *jb
ELECTRICAL SYSTEM - WIRING
02/02/200730000106/20/2002
 Tl*- the contact stated that while attempting to drive the 2002 volvo s40 he turned the key in the ignition and a thick black smoke came from the front driver side door panel and filled the interior of the vehicle immediately. the contact turned the vehicle off and exited the vehicle. the vehicle was taken to a volvo dealer and they could not find the cause of the smoke. the current and failure mileage were 30,000.*ak
ENGINE AND ENGINE COOLING
03/01/2002300005840
 Tl* - the contact owns a 2002 volvo s40. the contact stated that the enginewas idling high. volvo stated that the vehicle was operating normally. the rpm surge occurred frequently when the contactwas driving the vehicle. the check engine light came on periodically. there was a recall for this failure on all volvo models, but not for the 240 model. *ak
07/20/200575700107/20/2002
 Vehicle being reported is a 2002 volvo s40 sedan. traveling on us route 13 south of dover, de. and slowed down for a traffic light in medium traffic from a speed of approximately 55 mph. vehicle stalled without warning during deceleration. vehicle restarted with some effort. at next light, situation repeated itself - vehicle stalled without warning during deceleration. placed transmission in neutral to coast while attempting to restart. vehicle restarted only when accelerator was partially depressed causing engine to rev up. vehicle continued to stall when speed dropped to approximately 25-30 mph unless the accelerator was depressed to maintain engine rpm while brakes were being applied to slow vehicle down. critical situation traveling in area with low speed limits and traffic control devices such as stop signs and traffic lights. vehicle was taken to local volvo dealer who determined that a device that controls the air going into the engine was at fault. repairs were made at a total cost of $600. *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER
11/26/20053
 I purchased a 2002 volvo s40 which from the dealership in june 2002. it was my first new car. about a year and half ago, without a warning light -coming on to alert me of an impending problem, the car began emitting heavy black smoke from the exhaust system. the car had gone through an oil change just 200 miles before. when the car was brought to the dealership, they informed me that due to my waiting too long to change oil, the turbo failed and oil may have gotten into the engine, making it necessary for me to replace the engine and the turbo. the dealership refused to honor the warranty and insisted that i spend a $3000-$6000 for the repair/replacement after some discussion, the dealership proposed cleaning the engine and replacing the turbo as an alternative. as the price was exorbitant, i took the car to an independent repair shop which performed the turbo replacement and engine clean-up, changing the oil and coolant. the car ran fine without a problem until 11/26/05 when the engine, at 57,000 miles but out of warranty, began emitting white smoke at the front and rear of the car. fortunately i was able to drive the car to a reputable repair shop which diagnosed the problem as a turbo failure (failure #2). the engine was cleaned as best the shop could and the turbo replaced at substantial expense. when the repair was completed, i drove the car 200 miles to bring it home without incident. the next morning it began to make odd noises. i took it to the dealership and was told that the engine needed replacement and the turbo had broken (failure #3)--price tag $6600. i am convinced that i was sold a defective s40 at the outset,and the problems i've experienced i relate to the dealers unwillingness to honor the warranty when it was still alive and fix the defective engine/turbo on a new car. i will never buy another volvo, and i do not recommend that anyone else buy one . *jb
EXTERIOR LIGHTING - HEADLIGHTS
05/18/200720002003/09/2003
 Types of recurring issues with volvo s40: headlights, driver front window motor, early brake pad wear. headlight bulbs were replaced 2-3 times a year at consumer's cost. when brought to the attention of volvo dealer they reported that it was probably due to lights being used during daylight. they check electrical and reported no issue. had brake pad and rotor issued shortly after purchasing the vehicle. volvo dealer reported volvo rotors were built thin and soft. cost of brake replacement was not covered under warranty as it was considered regular wear. driver side window regulator has been replaced three times. first regulator was replaced in june 2005, then february 2006 and now may 2007. may 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.*ak
08/09/20054
 I bought a 2002 volvo s40 from an individual in january of 2004. in a matter of 3 months in 2005, i had to replace my passenger headlight 3 different times and my driver headlight 2 different times. i called the volvo dealer and they said that a bulb should last around 2 years. in the next month, my passenger headlight went out again. i got under the hood to replace it as usual. when i pulled the black plastic piece that contains the male part to the wire connection and acts as the bulb socket, it was melted. it was melted to the point that i could not get the bulb out until i used pliers. i took my car to the volvo dealer and they said that i would have to replace the whole headlight compartment. since volvo headlight compartments are factory sealed, they would not break the seal. i would have to buy a brand new one @ $500. i did not do anything about it, because i am not paying for a whole new headlight compartment for a piece of plastic the size of my thumb. two days later, the driver side bulb went out and it did the same exact thing, melted. this left me with no headlights! without $1000 to spend on two new headlight compartments (installed), i drove during the day. i found, myself, that the wires (positive and negative) that are connected to the black plastic socket are fairly close together and are not shielded from one another. so, when the wiring harness for the headlights was put together, they did not place the wires nice and neat in there to where there was no way they would touch. when i came to this conclusion, i put black electrical tape around the two wires (positive and negative) in each headlight compartment so that nothing about the wire would touch and obviously had to put new bulbs in. this happened during the second and third week of august 2005. since, i have not had any problems. i have also replaced both license plates bulbs, the rear fog light bulb, and all four brake lights. *nm
03/01/20055
 Volvo s40 2002 headlights burned out, replaced 4-5 times. *bf the consumer believed this to be potentially dangerous since the head lights were being used as daytime running lights. *jb
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
10/25/200572872105/05/2002
 Crack in upper tank of sending unit resulting in gas leakage. 15 month old daughter may have been affected by the toxic fumes. *nm
OTHER
01/21/20031
 Consumer requested all complaints, recalls, concerns and accidents listed for a 2002 volvo s40. *dt *jb
POWER TRAIN - AUTOMATIC TRANSMISSION
06/06/20091
 Front end suspension isn't right,pulls when driving and there is a knocking items nhtsa 10016415 and 630879. check engine has always been on 10003441. there is a clunking noise when shifting 10003398. there was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for inspection in nc. *tr
06/22/200742000210/21/2003
 Tl*the contact owns a 2002 volvo s40. the vehicle hesitated when it was started by the contact. the winter weather driving warning indicator arrow and the check engine light illuminated while driving 5 mph. the check engine light remained illuminated after turning the vehicle on an off. on june 23, 2007, the dealer advised the contact not to drive the vehicle until it was diagnosed. the dealer stated that the vehicle had a faulty transmission control module and the original battery was weak. the estimated cost of repair is $1,000, which does not guarantee that the failure will not recur. the current and failure mileages were 42,000.
SEAT BELTS - FRONT
01/11/20031
 The consumer sustained major injuries when the vehicle struck a tree. the seat belt didn't hold him in place and the air bags didn't deploy. *ph *sc *jb
SERVICE BRAKES, HYDRAULIC
08/24/2011150000
 Tl* the contact owns a 2002 volvo s40. the contact stated that the brakes were applied while reversing and the pedal traveled to the floorboard abnormally. the contact took the vehicle to a local mechanic where the mechanic advised that there was a crack in the master cylinder. the master cylinder was replaced however, the failure recurred while in reverse. the mechanic was contacted a second time who advised the contact of nhtsa campaign id number: 04v493000 (service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings) and informed the contact to call a dealer. the contact called the dealer regarding the recall but the dealer stated that the vin was not included. the vehicle was not further repaired. the failure mileage was 150,000.
08/24/2011150000
 Tl-the contact owns a 2002 volvo s40. the contact stated that the brakes were applied while reversing and the pedal traveled to the floorboard abnormally. the contact took the vehicle to a local mechanic where the mechanic advised that there was a crack in the master cylinder. the master cylinder was replaced however, the failure recurred while in reverse. the mechanic was contacted a second time who advised the contact of nhtsa campaign id number: 04v493000 (service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings) and informed the contact to call a dealer. the contact called the dealer regarding the recall but the dealer stated that the vin was not included. the vehicle was not further repaired. the failure mileage was 150,000. kmj
08/24/2011150000
 Tl-the contact owns a 2002 volvo s40. the contact stated while in reverse and applying the brakes the brake pedal went all the way to the floor. the contact shifted the vehicle out of reverse to stop the vehicle. the contact took the vehicle to a local mechanic and the mechanic stated their was a crack in the master cylinder. the mechanic replaced the master cylinder. after the repair while in reverse and braking the brake pedal went to the floor again. the contact called the mechanic and the mechanic informed the contact about a nhtsa campaign i.d. number 04v493000 (service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings) and informed the contact to call a dealer. the contact called the dealer regarding a the recall and the dealer stated the vehicle was not included in the recall due to the vin number. the contact stated this is a serious safety issue. the failure mileage was 150,000. jo
10/20/2010104000
 Tl-the contact owns a 2002 volvo s40. while driving 30 mph as the vehicle in front of the contacts vehicle slowed down the contact engaged the brake. the brakes felt hard and failed. she crashed into the vehicle in front of her. the contact was not injured. a police report was filed. no damages were done to the other vehicle. the contact stated the vehicle had front end damages. the vehicle was repaired. the contact stated the local mechanic replaced all the left front lights, the hood, the bumper and the fender. the failure mileage was 104,000 and the current mileage was 104,900. vwb
SERVICE BRAKES, HYDRAULIC - ANTILOCK
08/06/2002
 Aniti-lock brakes are not working properly, do not grab like they should and click. contacted dealer. this was common problem.*ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - PADS
05/18/200720002003/09/2003
 Types of recurring issues with volvo s40: headlights, driver front window motor, early brake pad wear. headlight bulbs were replaced 2-3 times a year at consumer's cost. when brought to the attention of volvo dealer they reported that it was probably due to lights being used during daylight. they check electrical and reported no issue. had brake pad and rotor issued shortly after purchasing the vehicle. volvo dealer reported volvo rotors were built thin and soft. cost of brake replacement was not covered under warranty as it was considered regular wear. driver side window regulator has been replaced three times. first regulator was replaced in june 2005, then february 2006 and now may 2007. may 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.*ak
05/10/200321000102/06/2002
 The rear brake pads on my 2002 s40 volvo wore out at about 21 thousand miles and ruined the rotor. according to volvo corp. this is becasue the government is has prohibited them from using asbestos in the brake pads. volvo put noise making squealeres on the inside pads but due to the design of the brakes the outside pads wear out first causing a rivit on the pad to contact the rotor and ruin it before the pads can be replaced. according to three volvo service managers it is normal for the pads to wearout at between 15 and 20,000 miles.i have contacted volvo of america by email on two occasions to advise them of the obvious problem with their brakes they advised me they could offer me no reimbursement for the premature brake failure and would file the information .*ak
SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - ROTOR
07/18/20041
 I was slowing down on the interstate for my exit and my steering wheel starting shaking severely to the point that i was barely able to contain it this was when i decided to take my s40 to the dealership. i had noticed some shaking previously but wasn't sure what the problem was and since my car had just been serviced i figured anything serious would have been identified. when i took my car in i was told that i needed new rotors and pads. my mileage seemed rather low for my rotors to be shot so i asked why this might have happened as i work from home. i was told it was probably due to lack of driving. the dealership covered the rotors under my warrenty but charged me for the brake pads which made no sense as i would not have needed new pads if it hadn't been for the rotors being shot.*ak
SUSPENSION
01/02/20131148001
 While driving the right front and right rear coil springs broke and the front coil spring damaged the tire. dealer stocks these expensive springs (both front and rear) in larger than normal amounts due to incidences of breakage. i feel that this was an early failure for this type and age of vehicle and should it have been a a higher speed the incident could have been severe. *tr
01/02/2013114800
 While driving the right front and right rear coil springs broke and the front coil spring damaged the tire. dealer stocks these expensive springs (both front and rear) in larger than normal amounts due to incidences of breakage. i feel that this was an early failure for this type and age of vehicle and should it have been a a higher speed the incident could have been severe.
06/06/20091
 Front end suspension isn't right,pulls when driving and there is a knocking items nhtsa 10016415 and 630879. check engine has always been on 10003441. there is a clunking noise when shifting 10003398. there was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for inspection in nc. *tr
SUSPENSION - FRONT
06/06/20091
 Front end suspension isn't right,pulls when driving and there is a knocking items nhtsa 10016415 and 630879. check engine has always been on 10003441. there is a clunking noise when shifting 10003398. there was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for inspection in nc. *tr
SUSPENSION - REAR - SPRINGS
03/01/200740000210/01/2002
 Both rear springs broke, vehicle had less then 40k miles. *tr
VEHICLE SPEED CONTROL
08/21/20031
 While driving at a very low speed, the vehicle suddenly accelerated. the driver was able to stop the vehicle by pressing on the brake pedal really hard. the vehicle was towed to the dealer. *ak *jb
VISIBILITY - POWER WINDOW DEVICES AND CONTROLS
05/18/200720002003/09/2003
 Types of recurring issues with volvo s40: headlights, driver front window motor, early brake pad wear. headlight bulbs were replaced 2-3 times a year at consumer's cost. when brought to the attention of volvo dealer they reported that it was probably due to lights being used during daylight. they check electrical and reported no issue. had brake pad and rotor issued shortly after purchasing the vehicle. volvo dealer reported volvo rotors were built thin and soft. cost of brake replacement was not covered under warranty as it was considered regular wear. driver side window regulator has been replaced three times. first regulator was replaced in june 2005, then february 2006 and now may 2007. may 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.*ak
VISIBILITY - WINDSHIELD
07/01/2002
 There is a dangerous reflection of the taupe dash off the windshield of my new volvo, which the company has refused to acknowledge. others have noticed this as well: see www.volvospy.com. this creates a very dangerous situation in daylight, so much so that the glare in daylight, present when the sun is shining and even on an overcast day, prevents one from an unobstructed view. the company's response to my complaint was our vehicles meet or exceed all united states specifications for safety brfore they are released to customers is there a specification for the amount of glare allowed? further, they say that they can not be responsible for when and the way i drive, but with all due respect. i'm sure i'm not the only one who drives in daylight hours. the dealer suggests that i cover the dash with a dark colored material, which does, indeed, cut the glare; others have suggested wearing polarized sunglasses, which also works. but neither of these suggestions is satisfactory, especially in a new car. are you aware of this problem? and do you have any suggestions? this is not a trivial problem. the glare is almost blinding at times. check it out and see what i mean. dt

Car dealers selling


StateCityZipNamePhone
ARLITTLE ROCKNORTH POINT VOLVO501-218-1573
MDEASTON21601DAVID WHEELER VOLVO800-327-4754
NYSMITHTOWN11787GEORGETOWN VOLVO OF SMITHTOWN631-724-0400
OHCOLUMBUS43213BYERS VOLVO8009422745
OKOKLAHOMA CITYBOB HOWARD VOLVO
ORBEAVERTON97005HERZOG-MEIER AUTO CENTER503-644-9121
TXEL PASO79924HOY FOX VOLVO915-778-5341
VTSHELBURNE05482ALMARTIN VOLVO802)985-1030