The 2006 S40 is a compact Volvo built on Ford's European C1 platform with shared Mazda/Focus underpinnings. Solid bones, but known for catastrophic turbo oil-consumption issues and expensive transmission cooler failures that can grenade the transmission if ignored.
Turbo Engine Oil Consumption / PCV System Failure (2.5T)
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Burning 1+ quart per 1,000 miles, Blue smoke on startup or acceleration, Fouled spark plugs, Check engine light with misfire codes, Engine can seize if oil runs critically low
Fix: Root cause is PCV system allowing crankcase pressure to push oil past rings. Full fix requires PCV replacement, often combined with piston ring service or short-block if damage is done. If caught early, PCV and valve cover update is 3-4 hours; if rings are scored, expect 18-25 hours for engine-out rebuild.
Estimated cost: $800-1,200 for PCV system overhaul; $4,500-7,500 for short block or full rebuild with rings/bearings
Transmission Oil Cooler Line Failure
Common · high severity
Typical onset: 70,000-120,000 mi
Symptoms: Pink or milky transmission fluid (coolant contamination), Transmission slipping or erratic shifts, Overheating transmission, Coolant in trans can destroy clutch packs within days
Fix: Factory cooler lines corrode internally and leak coolant into ATF or vice versa. Requires immediate cooler line replacement, transmission flush, and often torque converter replacement. If driven after contamination, full transmission rebuild needed. Line replacement is 3-4 hours; transmission rebuild adds 12-16 hours.
Estimated cost: $800-1,400 for lines and flush if caught immediately; $3,500-5,500 for transmission rebuild if contamination caused damage
Angle Gear Seal Leaks (AWD models)
Common · medium severity
Typical onset: 60,000-110,000 mi
Symptoms: Fluid dripping from rear of transmission/transfer case area, Clunking or binding when turning (if fluid level drops), Visible wetness around angle gear housing
Symptoms: Loud whining, especially at cold startup, Steering effort increases, Fluid leaks from pump or reservoir, Groan when turning at low speeds
Fix: Pump develops internal wear and seals fail. Replacement pump plus flush of system is standard fix. 2-2.5 hours.
Estimated cost: $550-850
Front Lower Control Arm Bushings
Common · low severity
Typical onset: 70,000-100,000 mi
Symptoms: Clunking over bumps, Steering wander or vague feel, Uneven tire wear on inner edges, Visible cracks in rubber bushings
Fix: Volvo used soft bushings that deteriorate faster than competitors. Replace both lower control arms (bushings aren't serviceable separately on most). 2-2.5 hours for the pair.
Estimated cost: $500-800
Fuel Pump Driver Module Failure
Occasional · high severity
Symptoms: No-start or intermittent stalling, Fuel pump doesn't prime on key-on, Dies while driving, restarts after cooling, No fuel pressure
Fix: Electronic module that powers the fuel pump fails due to heat and poor solder joints. Module is under rear seat or in trunk area depending on model. 1-1.5 hours to replace.
Estimated cost: $400-650
Throttle Body Carbon Buildup (Drive-by-Wire)
Occasional · low severity
Typical onset: 60,000-90,000 mi
Symptoms: Rough or high idle, Hesitation on throttle tip-in, Check engine light with throttle adaptation codes, Stalling at stops
Fix: Electronic throttle body accumulates carbon on butterfly valve. Remove and clean thoroughly, then perform throttle adaptation with VIDA or equivalent scanner. 1.5 hours.
Estimated cost: $200-350
Owner tips
Check oil every 500 miles on turbo models — consumption starts subtly then accelerates
Inspect transmission fluid color monthly; any pink tint means cooler contamination, stop driving immediately
AWD models: service Haldex unit every 30k and check angle gear for wetness
Use quality PCV parts (OEM or Genuine Volvo) — cheap aftermarket PCV valves fail in under 20k
Budget $1,500/year for maintenance beyond basics if buying over 100k miles
Buy the naturally-aspirated 2.4L if you find one; turbo models are ticking time bombs after 100k unless PCV system and trans cooler have been proactively addressed with records to prove it.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: European H6 configuration; battery located in trunk area
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Every control module on the 2005-2011 Volvo S40 — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
Power Steering Control Module (PSCM)2.0 hr R&Rdealer / factory tool +0.5 hr▸ programming details
📍 Steering column area or integrated with electric power steering motor
🔧 VIDA/DiCE
⚠️ Electric power steering only (not all models); calibration required after replacement; 2008+ models
📍 Integrated with CEM or separate module near ignition switch
🔧 VIDA/DiCE
⚠️ Key programming required; all keys must be present; typically integrated with CEM on this generation
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, REOCCURRING, LONG-TERM EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS SUCH AS SALTY-WET CONDITIONS, IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.
Consequence: IF THIS OCCURS, THE CHECK ENGINE LIGHT MAY ILLUMINATE. IN SOME CASES, THE VEHICLE MAY FAIL TO START OR MAY STALL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
FUEL SYSTEM, GASOLINE · 06V137000
2006-04-24
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH T5 TURBO ENGINES, THE POLYAMIDE TUBE IN THE FUEL LINE IS SENSITIVE TO THE EXTREME TEMPERATURES THAT MAY OCCUR IN THE AREA WHERE THE TURBO/EXHAUST MANIFOLD IS LOCATED.
Consequence: THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2006 Volvo S40 2.5L Turbo I5 and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.