2006 Volvo S40

2006 Volvo S40

Overview

The 2006 Volvo S40, a compact executive car, offered a blend of Scandinavian design, safety, and performance. It was available with various engine and transmission configurations, catering to different driver preferences. While generally considered a reliable vehicle, like any car, it has specific areas that have seen more frequent reports of issues. This analysis focuses on documented technical problems beyond routine maintenance, providing insights into potential concerns for owners and prospective buyers of this model year.

---

Engine

2.4L Naturally Aspirated (B5244S4)

Oil Leaks

• Symptoms: Visible oil stains under the vehicle, burning oil smell, low oil level.
• Solution: Replacement of seals and gaskets (e.g., valve cover gasket, oil pan gasket).
• Cost: $300 - $700

PCV System Clogging

• Symptoms: Rough idle, increased oil consumption, engine misfires, potential for oil leaks.
• Solution: Cleaning or replacement of the Positive Crankcase Ventilation (PCV) system components.
• Cost: $400 - $900

2.5L Turbocharged (B5254T2)

Turbocharger Issues

• Symptoms: Loss of power, whistling noises from the engine bay, increased exhaust smoke.
• Solution: Repair or replacement of the turbocharger unit.
• Cost: $1200 - $2500

Ignition Coil Failure

• Symptoms: Engine misfires, rough idling, check engine light illumination.
• Solution: Replacement of faulty ignition coils.
• Cost: $150 - $400

Transmission

5-Speed Automatic (AW55-50SN)

Harsh Shifting / Slipping

• Symptoms: Jerky gear changes, delayed engagement, slipping between gears.
• Solution: Transmission fluid flush and filter replacement, or potential rebuild/replacement.
• Cost: $500 - $3000

6-Speed Manual

Clutch Wear

• Symptoms: Slipping clutch, difficulty engaging gears, grinding noises.
• Solution: Replacement of clutch kit (clutch disc, pressure plate, release bearing).
• Cost: $800 - $1500

Suspension

Standard Chassis

Worn Control Arm Bushings

• Symptoms: Clunking noises over bumps, vague steering feel, uneven tire wear.
• Solution: Replacement of front control arm bushings.
• Cost: $300 - $600

Strut Mount Bearing Failure

• Symptoms: Popping or creaking noise when turning the steering wheel, especially at low speeds.
• Solution: Replacement of front strut mount bearings.
• Cost: $200 - $450

Electrical

General Electrical System

Window Regulator Failure

• Symptoms: Power windows not operating, slow window movement, grinding noise from door panel.
• Solution: Replacement of the window regulator mechanism.
• Cost: $250 - $500

CEM Module Issues

• Symptoms: Intermittent electrical faults, warning lights, non-functional accessories.
• Solution: Diagnosis and potential reprogramming or replacement of the Central Electronic Module (CEM).
• Cost: $600 - $1200

Exterior

Body Panels and Trim

No Major Issues

• Symptoms: No widespread issues reported.
• Solution: No widespread issues reported.
• Cost: N/A

Interior

Cabin Components

HVAC Blower Motor Resistor Failure

• Symptoms: Fan only works on highest setting, or not at all.
• Solution: Replacement of the blower motor resistor.
• Cost: $100 - $250

Sunroof Drain Clogs

• Symptoms: Water leaks into the cabin, damp carpets, potential for mold.
• Solution: Clearing of sunroof drainage channels.
• Cost: $150 - $300

---

Summary Verdict

The 2006 Volvo S40 is a generally dependable vehicle, particularly praised for its safety features and comfortable ride. Owners should be aware of potential issues related to oil leaks and PCV system clogging on the naturally aspirated engines, and turbocharger or ignition coil problems on the turbocharged variants. Automatic transmission issues like harsh shifting can occur and may require significant repair. Suspension components, especially bushings and strut mounts, can wear over time. Electrical gremlins, such as window regulators and the CEM module, are also noted. While not immune to problems, addressing these common issues proactively can help maintain the S40’s reliability and enjoyment.