Volvo S40
Stronger D4 version of the 2.0-litre four-cylinder with 130 kW and higher injection pressure for 300 Nm torque. Two-stage turbocharging for better dynamics. Strictly observe service intervals; check the high-pressure injection pump on high-mileage vehicles.
Stronger compact diesel
130 kW D4 VEA in the compacts: adequate for relaxed driving. In the C30, almost sporty.
Engine Weaknesses 4
The D5204 engines are VEA successor engines with an identical EGR cooler problem. Soot paste in the EGR system leads to throttling. The 2020 recall also applies to vehicles with D5204 engines.
Symptoms: EGR fault light, engine throttling, rough running, increased fuel consumption
On the D5204T6, a breaking serpentine belt can get into the timing belt drive and cause severe engine damage. Inspect timing belt and serpentine belt condition together at every service. Timing belt replacement interval: 105,000 km or 10 years.
Symptoms: Scraping or clattering from the engine area, sudden engine stall, tensioner noises.
The VEA successor D5204 has the same DPF vulnerability with short-trip use. Regular long-distance runs for active regeneration are necessary. DPF cleaning or replacement from 150,000 km.
Symptoms: DPF warning light, power loss, increased diesel consumption
The more heavily turbocharged D5204T6 shows injector leakage at higher mileages from the high injection pressure. Diesel enters the engine oil, dilutes it, and accelerates bearing wear. Check oil level and condition regularly.
Symptoms: Diesel in engine oil (oil level rises, diesel smell), rough idle, excessive fuel consumption, soot smell.
Reports & Tests
255 owner complaints filed with NHTSA (2004–2012). Most reported: Electrical (70), Brakes (33), Airbags (27).