Premium Swedish hatchback popular with families and commuters. Economical diesel returns 55-60 mpg in real-world driving. Two different D2 engines: early cars use problematic Ford/PSA 1.6 diesel (head gaskets, injectors, cracked blocks) while post-2016 models feature more reliable Volvo-built 2.0 VEA engine. Main concerns: DPF blockage on short journeys, EGR valve failures (especially on 2.0), clutch slave cylinder issues, door lock actuators, and coolant leak fire recall (2012-2015). Avoid the 1.6 diesel if possible - the 2.0 is smoother, more powerful, and generally more reliable despite its EGR issues.
EGR cooler clogs with sludge causing limp mode, reduced power · more· less
The 2.0 VEA engine has persistent EGR issues - the cooler becomes over-cooled causing sludge buildup. When it fails, the entire EGR valve, condenser (cooler) and pipework must be replaced. Volvo dealers quote around €1,600 but sometimes offer goodwill contributions. Later Volvo fixes include rerouted pipework for less cooling. The 1.6 diesel also suffers EGR problems but less frequently. Symptoms include engine warning light, limp mode, and reduced performance. Affects nearly every 2.0 D2/D3/D4 engine at some point. Verify the latest fix has been applied by a Volvo dealer before purchase.
DPF blockage and regeneration failures€400 - €1,500
Diesel particulate filter clogs on short journeys, causes limp mode · more· less
If driven predominantly on short trips in cold weather, the DPF never completes its regeneration cycle (needs 10-20 minutes at operating temperature). Warning signs: cooling fans running after engine stops, "Particle Filter Full" message, limp mode with reduced power. At 45g soot the DPF must be replaced. Forum reports show many D2 owners experience check-engine lights, limp mode, and black smoke from clogged DPF. Forced regeneration via motorway driving (100-120 km/h at 2000+ RPM for 20+ minutes) can clear minor blockages. Complete DPF replacement costs €400-1,500 depending on parts quality. Not suitable for city-only driving.
Slave cylinder leaks, makes clutch pedal stiff or causes engagement issues · more· less
Known issue on V40s using Ford petrol and Ford/PSA diesel engines with B6/M76 gearbox - same fault affects Ford Focus Mk3. The clutch slave cylinder fails, causing extremely stiff clutch pedal or clutch disengagement problems. Cylinder fills with friction particles from the clutch. Because it's mounted inside the transmission housing, replacement requires gearbox removal, significantly increasing labor costs. Owners report £1,500 total cost including clutch replacement. Some have contacted Volvo UK for partial cost contribution. Often coincides with premature clutch wear on the 1.6 diesel models.
Ford/PSA 1.6 diesel prone to cracked blocks from cooling system pressure · more· less
The early 1.6 D2 (2012-2015) uses a problematic Ford/PSA engine. High pressure builds in the cooling system causing pipes to swell and potentially crack the engine block. Signs include coolant system pressurizing, overheating, damaged cylinder head and head gasket. Forum mechanics report this is "a very common problem with the 1.6 diesel" though proper coolant maintenance reduces risk. This engine also suffered from injector seal leaks, carbon buildup causing turbo failure, and was "very vulnerable to sudden overheats which would go beyond repair." Engine replacement is the only solution for cracked blocks. Strongly recommend avoiding 2012-2015 1.6 D2 models - buy 2016+ with 2.0 VEA engine instead.
Door lock actuator failure€280 - €500
Electronic door locks stop working, only manual operation remains · more· less
What Car? Reliability Survey reports numerous V40 owners experiencing door lock failures. The door lock actuator is a mechanical component that operates every time you lock/unlock - it gets heavy use and fails frequently. When failed, one or more doors won't lock electronically though manual locks still work. Common part shared with 2011+ S60/V60. Dealers charge €500+ and often replace the door panel (damaged during removal). Independent repair costs €280-320 per actuator. DIY is possible with T25/T30 screwdrivers and trim removal tools. Can be expensive once outside the 3-year/60,000-mile warranty.
Coolant leak fire risk (2012-2015 recall)€0 (recall)
Exhaust manifold gasket fails under high load when cold, can cause fire · more· less
Volvo recalled 3,192 V40/V40CC cars built 06/02/2012 to 22/04/2015 for coolant leak fire risk. During warm-up under high engine load (hard acceleration when cold in cold climates), overpressure in the coolant circuit can cause the exhaust manifold gasket to fail. This can lead to coolant and oil leaks onto hot exhaust components, potentially causing smoke or slow-developing fire. Only affects 1.6 Ford EcoBoost B4164T engines. Recall fix: modify coolant bypass valve and install new exhaust manifold gasket. Verify recall completed with VIN check before purchase. Driver will receive low coolant warning before fire risk.
Carbon buildup from gentle driving causes actuator to stick, turbo can fail · more· less
If the V40 D2 is driven too gently or only on short trips, carbon builds up in the turbo actuator causing it to stick. Symptoms include sudden limp mode, loss of power, and dashboard warning lights. Turbo actuator reconditioning costs around €350, but full turbo replacement ranges €800-2,000 depending on internal damage. Cars used for short-distance city driving can also suffer oil dilution from aborted DPF regeneration attempts, leading to turbo oil seal/bearing failure. Using premium fuel and regular spirited driving helps prevent carbon buildup. Average turbo lifespan is 100,000-125,000 miles under normal conditions.
Faulty gear selector rod makes 5th gear hard to engage · more· less
Some V40s with M76 manual transmission suffer from difficulty engaging fifth gear due to worn gear selector rod assembly. Volvo developed a spacer (part 32240062) that can be fitted to the selector assembly to fix the issue. DIY repair involves removing trim panels around gear selector, fitting the spacer, and reassembling. Parts cost around €50, or €150-200 at a garage. Does not require gearbox removal. This is separate from the general manual transmission issues like worn linkage and synchro ring problems that affect higher gear engagement.
The V40's air-conditioning drain hose can become blocked with debris, causing water to back up and leak into the footwell. Carpets act like a sponge, holding moisture and creating musty, moldy smells. If A/C runs but no water drains under the car, the hose is blocked. Clearing the blocked drain (squeeze and wiggle to dislodge crud) can release over a pint of trapped water. Solutions: clear drain hose, replace cabin air filter, use deodorizing "bomb" while running A/C, enable afterblow function in VIDA to dry evaporator after use. Turn off A/C a few blocks before destination to let fresh air dry the system. Some dealers can enable afterblow function.
The V40 D2 has two very different engines. The 2012-2015 Ford/PSA 1.6 diesel (D4162T) has serious reliability issues including cracked blocks, head gasket failures, and premature clutch wear. The 2016-2019 Volvo-built 2.0 VEA engine is significantly more reliable despite persistent EGR valve problems. Buy 2016 or newer if possible. Avoid short-journey-only diesel ownership - DPF and EGR issues are guaranteed.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Volvo dealer or specialist records essential. Verify oil changes at proper intervals. D2 requires 12-month/12,500-mile service intervals.
Cold start
Must start engine completely cold. Listen for unusual sounds, excessive smoke, or rough idle.
Test drive
Minimum 20 minutes including motorway speeds to warm DPF and check for regeneration issues.
Body condition
Check for rust, accident damage, paint mismatch. Volvo V40 generally resistant to corrosion.
Specific for this vehicle
Verify coolant leak fire recall completed (2012-2015)
Cars built 06/02/2012 to 22/04/2015 affected. Contact Volvo with VIN to confirm recall work completed. Critical safety issue.
Check for DPF warning lights and regeneration
Watch for "Particle Filter Full" message. After test drive, check if cooling fans run after engine stops (interrupted regeneration). Ask seller about frequency of motorway driving.
Test clutch pedal feel (manual gearbox)
Pedal should not be excessively stiff or spongy. Check engagement point. Try engaging all gears including 5th. Stiff pedal indicates slave cylinder failure.
Test all door locks electronically
Lock and unlock all doors using key fob. All doors should lock/unlock simultaneously. Manual operation should work even if electronic fails.
Check for musty smell and damp carpets
Turn on A/C, check for mold smell. Feel carpets in footwells and boot for dampness. Look for water pooling under car after A/C use.
Verify engine variant (critical)
Confirm whether 1.6 D4162T (2012-2015) or 2.0 D4204T VEA (2016-2019). Check engine code on VIN plate or service records. Strongly prefer 2.0 VEA engine.
Check for EGR valve issues
On 2.0 VEA engines, ask if EGR valve/cooler has been replaced. Check for engine warning lights or reduced power. Verify latest Volvo EGR fix applied.
Inspect for coolant leaks and overheating history
Check coolant level and condition (should not be brown/milky). Look for leaks around exhaust manifold. Ask about any overheating incidents (critical for 1.6 diesel).
Listen for turbo actuator issues
During test drive, check for smooth power delivery. Any sudden loss of power, limp mode, or warning lights suggest turbo actuator or turbo failure.
Recalls and Technical Service Bulletins
Coolant leak fire risk (2012-2015, 1.6 engine)Verify completed
Contact Volvo dealer with VIN to verify all recalls completed. The coolant leak fire recall is particularly critical for 2012-2015 models. Volvo recall information available from August 1999 onwards at volvocars.com.
Warranty Status
Factory warranty (3 years / 60,000 miles)Expired on all V40s
Roadside assistance (1 year standard)Extended free when serviced at Volvo dealer
Corrosion warranty (12 years unlimited miles)May still apply to 2012-2013 models
All V40s are now outside their original 3-year/60,000-mile warranty. Extended warranties may be available through Volvo dealers. The 12-year corrosion warranty may still apply to earliest models. Servicing at Volvo dealer extends roadside assistance coverage.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.