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Volvo · Known Issues

2009 Volvo S40 Problems: 5 Known Issues

2009 model year · 4,280+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 4,280+ owner reports, the 2009 Volvo S40 has 5 documented known issues, with 4 rated critical. The most serious are PCV System Failure Causing Oil Leaks and Engine Damage ($300-$1,500 repair), Electronic Throttle Module (ETM) Failure ($250-$800 repair), T5 Turbocharger Failure from Oil Starvation ($1,200-$3,500 repair) and Electric Power Steering Pump Failure ($400-$1,000 repair). The most commonly reported issue is PCV System Failure Causing Oil Leaks and Engine Damage with 2,200 owner reports. Across all issues with published estimates, repair costs range from $100 to $3,500. DIY maintenance guides at au7o.io.

In This Article

  • S40 Engine3
  • S40 Steering1
  • S40 Drivetrain1
  • Recalls4
  • FAQ
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In This Article

  • Engine3
  • Steering1
  • Drivetrain1
  • Recalls4
  • FAQ

All 5 Known Issues

Filter:
ALL YEARS201220112010200920082007200620052004
Community reported
2,200 owners

On the 2004-2012 Volvo S40 2.5L T5, 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 engine - rear main seal, valve cover gaskets, oil filter housing, and turbo seals. Left unchecked, the crankcase overpressure can push the rear main seal out, causing catastrophic oil loss. The PCV system should be treated as a maintenance item on these engines. The issue affects all P1 platform Volvos including S40, V50, C30, and C70.

Common Symptoms

  • Oil leaks from multiple locations simultaneously
  • Rough idle and misfires
  • Whistling noise from engine bay (vacuum leak through PCV)
  • Check engine light with lean codes (P0171)
  • Oil pooling on top of transmission (rear main seal leak)
  • White smoke from exhaust (oil in intake)

How to Fix

Replace the entire PCV system including oil trap/separator (Volvo part 31338023), breather hoses, and PCV valve. This is a $100-200 parts job but 3-4 hours labor due to the system's location behind the intake manifold. Replace any damaged seals (rear main seal, valve cover gasket) that leaked due to excessive pressure. Clean intake manifold of oil deposits. Prevention: replace PCV system every 80,000-100,000 miles. Use an OEM or Mann+Hummel PCV unit - cheap aftermarket units fail quickly.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • IPD 140064 early non-PTC P1 oil-separator diaphragm

    replace a confirmed torn diaphragm in a serviceable early non-PTC oil-filter-housing separator Fitment/availability: 2004.5-2005 P1 Volvo S40 five-cylinder through engine serial 3285661 with the original non-PTC oil-separator box; inspec…

    IPD USA
  • IPD 142641 later PTC-style P1 five-cylinder PCV diaphragm, cap and spring kit

    replace a confirmed torn diaphragm in a serviceable later PTC-style oil-filter-housing separator Fitment/availability: 2006-up P1 Volvo S40 2.4i/T5 and 2004.5-2005 from engine serial 3285662 or an earlier car updated to the PTC-style hou…

    IPD USA

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$300 - $1,500

Research This Issue

Based on 2,200 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence2,200 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
Community reported
1,100 owners

On the 2004-2011 Volvo S40 B5244S, 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 severely limited power or refuses to rev above idle. The issue primarily affects pre-2008 models, as Volvo updated the ETM design. Volvo issued an extended warranty program for the ETM on affected models. The ETM failure is distinct from the P2 platform (older S60/V70) ETM issue but has similar symptoms.

Common Symptoms

  • Check engine light with throttle position codes (P0121, P0122, P0123)
  • Engine enters limp mode with limited power
  • Engine won't rev above 2,000-2,500 RPM
  • Hesitation or surging during acceleration
  • Engine stalling at idle

How to Fix

Replace the electronic throttle module (ETM). Updated Volvo part 30711552 or 31216665 depending on engine type. Bosch aftermarket units are also available. Clear fault codes after replacement and perform throttle body adaptation using VIDA diagnostic tool. Check for Volvo extended warranty coverage, which covered the ETM replacement for up to 10 years on some model years. The repair is straightforward - the ETM bolts to the intake manifold and can be replaced in under an hour.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Volvo 31216327 non-turbo five-cylinder throttle body

    replace a scan-data-confirmed internal throttle-body failure on the non-turbo gasoline branch Fitment/availability: Applicable Volvo S40 P1 non-turbo five-cylinder gasoline branch using OE 31216327; confirm VIN, engine code and installed…

    FCP Euro
  • Genuine Volvo 30711552 T5 fuel-injection throttle body

    replace a scan-data-confirmed internal T5 throttle-body failure after boost-control and wiring faults are excluded Fitment/availability: Applicable 2004.5-2011 Volvo S40 P1 T5 gasoline branch using OE 30711552; confirm VIN, B5254T engine…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$250 - $800

Research This Issue

Based on 1,100 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence1,100 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
Community reported
980 owners

On the 2004-2012 Volvo S40, 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 allowing sludge to form. The turbo bearings wear without adequate lubrication, causing shaft play that leads to oil leaking past the compressor seal (blue smoke) and eventual catastrophic failure. Many owners don't realize the PCV system failure is the root cause of their turbo failure.

Common Symptoms

  • Blue or white smoke from exhaust, especially under boost
  • Excessive turbo shaft play (visible wobble in compressor wheel)
  • Oil consumption increasing rapidly
  • Whining or grinding noise from turbo area
  • Loss of boost pressure
  • Oil in intercooler piping

How to Fix

Replace turbocharger (OEM Mitsubishi TD04L-14T, Volvo part 36002369, or BorgWarner aftermarket equivalent). CRITICAL: Replace the PCV system simultaneously - a new turbo will fail again quickly if the PCV system is still clogged. Replace the turbo oil feed line and banjo bolt screen. Flush intercooler and piping to remove oil residue. Use quality 5W-30 synthetic oil and change every 5,000 miles. Allow turbo to cool at idle for 30 seconds before shutting off after spirited driving.

Typical repair cost:$1,200 - $3,500

Research This Issue

Based on 980 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence980 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026

On the 2004-2011 Volvo S40, 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.

Common Symptoms

  • Heavy steering
  • Whining from power steering
  • Power steering warning light
  • Intermittent loss of assist
  • Grinding noise when turning

How to Fix

Replace the electric power steering pump assembly. Use genuine or OEM-quality parts. Flush the power steering fluid with Pentosin CHF 11S. Check for fluid contamination that may have caused pump damage.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Volvo 30775461KT P1 power-steering pump update kit

    replace a test-confirmed internally failed electrohydraulic pump using the updated Volvo configuration Fitment/availability: Applicable second-generation P1 Volvo S40 electrohydraulic steering branch shared with C30/C70/V50; confirm VIN,…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$400 - $1,000

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence

On the 2004-2011 Volvo S40, 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.

Common Symptoms

  • Vibration at idle
  • Lurch when shifting D to R
  • Engine rocks excessively
  • Clunking on acceleration

How to Fix

Replace the upper torque mount. Consider replacing all engine mounts as a set if they show wear. Use OEM mounts for proper vibration damping characteristics.

Typical repair cost:$100 - $350

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence
NHTSA Recalls4 recalls

STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

VOLVO IS RECALLING MY 2008-2009 VEHICLES. A SECTION OF THE POWER STEERING RETURN LINE HOSE WAS NOT PROPERLY VULCANIZED (CURED) AND DOES NOT MEET SPECIFICATIONS. IF THE POWER STEERING RETURN HOSE FAILS, A SUDDEN RUPTURE OF THE HOSE CAN OCCUR.

Campaign #08V32900023/07/2008

EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Campaign #10V56600008/11/2010

SEATS

VOLVO IS RECALLING CERTAIN PASSENGER VEHICLES EQUIPPED WITH POWER FRONT PASSENGER SEATS. THE FRONT SEAT RAIL'S DETECTION SYSTEM WAS MANUFACTURED INCORRECTLY AND MAY PERMIT THE PASSENGER TO FORWARD THE SEAT BEYOND THE INTENDED MAXIMUM.

Campaign #10V59100022/11/2010
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Frequently Asked Questions

What are the most common Volvo S40 problems?

According to Au7o's analysis of 4,280+ owner reports, the 2009 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 2009 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.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 4,280+ owner reports, NHTSA recalls, TSBs, and automotive forums.

STRUCTURE:FRAME AND MEMBERS

VOLVO IS RECALLING CERTAIN MODEL YEAR 2011 S40 PASSENGER VEHICLES. A CRACK ON THE TOP SIDE OF THE PASSENGER SIDE SUPPORT MEMBER IN THE ENGINE COMPARTMENT MAY HAVE DEVELOPED DURING THE FORMING PROCESS IN COMPONENT PRODUCTION.

Campaign #11V18600018/03/2011

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

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.