Volvo S40 Problems: 2nd Generation (2005 to 2012)

There is nothing particularly wrong with the S40, but it’s common to find a 2nd gen Volvo S40 with problems like rear caliper failure or worn motor mounts, since these are some of the issues it tends to have. Find out the top 5 issues you’ll typically find with the 2005 to 2012 Volvo S40 and how to fix them.

Top 5 2005 to 2012 Volvo S40 Problems (2nd Gen)

1A Auto mechanic standing in front of a 2nd gen Volvo S40 and reviewing its common problems

1. Fuel Rail Pressure Sensor Failure

Symptoms of Fuel Rail Pressure Sensor Failure

  • Lower engine power when accelerating
  • Lower engine power
  • Engine stalling
  • Increased fuel consumption
  • Check engine light

Causes of Fuel Rail Pressure Sensor Failure

The fuel rail pressure sensor reads how much fuel pressure is inside the fuel lines. You may notice the engine stalling at times, like when starting up the engine or when at a stop if the fuel rail pressure sensor is bad. Increased fuel consumption can also happen, and you might find yourself making more trips to the gas station more than usual.

How to Fix a Bad Fuel Rail Pressure Sensor

The fuel rail pressure sensor is located on the fuel rail at the front of the engine. You can test the sensor under idle, acceleration, and load with a scanner that can graph the fuel pressure. You can also test the sensor with a fuel gauge by connecting it to the fuel rail and running the car. If the fuel pressure is fine but the check engine light is still on, there is a problem with the sensor and you’ll need to replace it.

2. Worn Motor Mounts

2nd gen 2005 to 2012 Volvo S40 engine

Symptoms of Bad Motor Mounts

  • Vibration in the passenger compartment
  • Clunking noise from behind the dashboard or firewall

Causes of Bad Motor Mounts

Engine mounts support the motor and keep it from being directly bolted to the S40’s body. The motor mounts have two metal sections and a rubber section. The rubber section can crack or break, and they usually fail because the rubber has broken down over time. The lack of support from the defective motor mount can cause engine vibrations that can be felt in the cabin.

How to Fix Motor Mount Problems on the 2nd Gen Volvo S40

An assistant can help fix motor mount problems on the 2005 to 2012 Volvo S40. With the car parked and the hood open, the assistant can look at the mounts and motor and see if there is a lot of movement when the engine is revved. Have the driver put their foot on the brake and with someone viewing the engine from a safe position, see how it moves in drive and reverse. Excessive movement will indicate there is a problem with the engine mount.

You can also inspect the motor mounts for dryness, rotting, cracking, or damage. If the motor mount is damaged, replace it. We recommend replacing them all at once.

3. Headliner Problems

Sagging or torn headliner on a 2nd gen 2005 to 2012 Volvo S40

Symptoms of Headliner Problems on the 2005 to 2012 Volvo S40

  • Headliner inside the passenger compartment keeps falling from the ceiling

Causes of a Sagging or Torn Headliner

The headliner is known to lose its grip from the ceiling material over time. This can cause problems if the headliner on the 2005 to 2012 Volvo S40 falls and obstructs the drivers view in the rear view mirror.

How to Fix Headliner Tears

You can have a professional repair the headliner and replace the ceiling material. You can also try to spray adhesive and press the headliner back up into place, or replace it yourself.

More on how to fix a headliner yourself

4. Rear Caliper Failure

Rusted rotor on a 2005 to 2012 Volvo S40 with rear caliper problems
Rusted rotor on a 2005 to 2012 Volvo S40 with rear caliper problems

Symptoms of Rear Caliper Failure

  • Rust on the rotor while rest of brakes look fine
  • Car pulling to a certain direction when braking
  • Smell from defective brakes

Causes of Rear Caliper Failure

The brake caliper piston can seize, and this can prevent the brake pads from being to press against the rotor and safely stop the car. This constantly applied friction can cause a burning smell at the brakes and in some cases cause them to smoke. If the piston is frozen and is unable to press the pads out, the rotor can rust. The car may also feel like its pulling to one side when braking if one of the calipers is defective.

How to Fix Rear Caliper Failure

The piston on the 2nd gen S40’s calipers is a twist-type. This means you will need a special tool to retract it. The piston cannot simply be twisted with a set of pliers, but needs to be twisted and pushed in.

Check the slide pins on the caliper also and make sure they are greased and can move.

We recommend replacing the brake pads and rotor when replacing the brake caliper. If you’re replacing the brakes on one side, we recommend replacing them on the other.

Once complete, bleed the brakes.

5. Front Axle Problems

Symptoms of Front Axle Problems on the 2005 to 2012 Volvo S40

  • Clicking that amplifies when turning or accelerating
  • Grease sprayed underneath the car
  • Binding when turning the steering wheel

Causes of Front Axle Failure

The CV joints on the axle have boots that keep them greased and keep debris out. The CV joint allows the axle to spin at the same rate as the wheel when turning. This can create a lot of friction, so grease is needed to keep the joint from binding and to help dissipate heat. Sometimes the protective boot can rip, and this can let debris in and cause binding, which causes a clicking sound, and may spray axle grease on parts underneath the car.

How to Fix Front Axle Problems

If the protective boot on the axle is ripped or damaged, replace the axle. You might be able to replace the boot only, but we recommend replacing the entire axle since the other boot is likely to wear out soon. Remember to get a four-wheel alignment after finishing this repair.

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Volvo S40 Problems - 2nd Generation - 2005 to 2012 - 1A Auto
Article Name
Volvo S40 Problems - 2nd Generation - 2005 to 2012 - 1A Auto
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Find out the most common Volvo S40 problems owners experience as our expert mechanics review its top symptoms and fixes
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1A Auto
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