Volvo S40
Ford four-cylinder turbodiesel with 1.6 litres marketed as the Volvo DRIVe version. SOHC with timing belt and Euro 5 standard. Very economical; conceived for high-mileage drivers with an efficiency focus.
Economical and sensible
95 hp diesel in a compact: economical, quiet, no heart-racing. Right if efficiency is the priority.
Engine Weaknesses 4
The original 240,000 km (150,000-mile) replacement interval of the PSA-derived DV6 was reduced to 140,000 km (87,500 miles) in 2014. Older vehicles maintained on the original interval carry elevated risk.
Symptoms: Sudden engine failure without warning, engine damage on belt snap
The D4162T engine block can crack during overheating events (e.g. from untreated coolant loss). Reports of cracked blocks following coolant starvation are documented in English-language Volvo forums.
Symptoms: Coolant loss following overheating, engine noises, white smoke, engine oil in coolant
The DPF of the PSA DV6/D4162T requires motorway runs for regeneration. With predominantly urban use the filter clogs quickly. An interrupted regeneration cycle (e.g. from engine stall) accelerates clogging.
Symptoms: DPF warning light early after purchase, power reduction, increased fuel consumption, soot smell when parking
On the PSA-derived DV6 diesel, the injector copper seals at the cylinder head interface tend to leak. Cylinder 3 is statistically the most commonly affected; exhaust residues seep out along the outside of the injector.
Symptoms: Soot deposits on outside of injectors, rough running, poor cold-start behaviour
Reports & Tests
255 owner complaints filed with NHTSA (2004–2012). Most reported: Electrical (70), Brakes (33), Airbags (27).