Table 1 shows three common electrical system related problems of the 2003 Volvo S40.
| Problem Category | Number of Problems |
|---|---|
| Instrument Panel problems | |
| Ignition Switch problems | |
| Electrical System problems |
Got a check engine light on and tried to get a full diagnostic test done, but the power control module was not communicating with vehicle.
I returned to my car and found that I could not turn the ignition switch and as a result of the security system my car was totally inoperative. The car had to be towed to the nearest dealer, where it was diagnosed with a broken ignition switch, specifically the device that reads the chip in the key has failed and will not accept any key. Currently the car has been sitting at the dealer for over 4 weeks. Because the keys and switches are matched we cannot get an after-market replacement switch. Further, the parts are back ordered at the dealer, back ordered at Volvo north America, back ordered at Volvo in sweden, and they cannot even get me a date when the part might be available. As an reliability engineer, the ignition switch failure would be classified as a criticality 1, single point failure, in other words it results in loss of vehicle. There is no indication of pending failure, and no way to mitigate the problem if it occurs. You are stranded where ever the car was last parked. And worse, in this condition the car has no resale value, except maybe at a "chop shop", so I cannot even trade it in for a new car.
Prior to latest incident, the car had occasionally gone into "limp" mode, sticking in 3rd gear but drivable. That problem would go away after a day or so. Local shop couldn't find anything definitive. Bigger problem was yesterday evening's loss of throttle control and multiple electrical issues. Idle throttle setting (eg stopped at lights) became unstable, occasionally revving upto to ~2000rpm. Moments later on suburban divided main street, throttle stuck at ~2200rpm which meant I was doing 45mph (straight line) without any pressure applied to gas pedal. Slowed on the brakes until I shifted into neutral at which time everything died (electrical) and came to a stop, short of traffic lights. Time of incident approx 8pm est (dark), roadway fully lit thankfully. Car was pushed off street. Some electrics came back on when tried but full christmas tree lights (ie everything) across entire dash. Towed home. Removed ignition key (was inserted to ensure steering was unlocked) but radiator cooling fan remained on (engine hadn't run for 2. 5 hours by that time). Pulled a fuse under the hood to stop it dumping the battery. Car is no youngster, manuf 2003 in netherlands, purchased second hand in 2005 with approx 20,000 miles on the clock. Currently at 108,000 ish. Other issues with car (not safety related) means I wont be having it fixed given its age and general cosmetic condition. It will be donated for scrap.