Ignition coils / spark plugs
usually 80,000–150,000 km · Wear part
Signs: Misfire, flashing engine light
Fix: Replace coil and plugs
€100–300
Common faults, service intervals and costs
Volvo S40 / V40 I
1995–2004 · Volvo S40 / V40 1
1
engines covered
5
known faults
6,557
roadworthiness tests in the statistics
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
The Volvo S40 / V40 I was built from 1995 to 2004.
For this generation we cover 1 engines and 5 known faults, each with the mileage range where it usually appears.
The most expensive known risk is Catalytic converter: it usually appears at 180,000–260,000 km and costs €500–1,500 to fix.
In UK roadworthiness tests in 2024, at 150–200 thousand km this model most often failed on: lights, wipers and visibility (28.2 %), suspension (19.3 %), brakes (17.4 %). It fails more often than an average car of the same age and mileage on: steering.
Engines
| Engine | Fuel | Timing drive | Oil |
|---|---|---|---|
| Petrol engine | Petrol | Check manual | — |
Faults by engine
Petrol engine
Water pump
usually 100,000–160,000 km · Medium risk
Signs: Coolant loss
Fix: Replace pump
€250–500
Catalytic converter
usually 180,000–260,000 km · Medium risk
Signs: Rattle, efficiency code
Fix: Replace
€500–1,500
Gearboxes
Manual
Clutch wear
usually 120,000–200,000 km · Medium risk
Signs: Slipping, high bite point
Fix: Replace clutch kit
€500–900
Geartronic (Aisin / GM)
Aisin TF-80SC harsh shifts / valve body
usually 120,000–220,000 km · Medium risk
Signs: Harsh 2–3 / 3–4 shifts, flare
Fix: Fluid flush; valve body
€300–1,500
Scheduled service
Intervals and typical prices for the Petrol engine engine. Other engines differ in oil, timing drive and some filters; the app gives the exact plan.
| Item | Interval | Typical price |
|---|---|---|
| Engine oil + oil filterEngine | every 15,000 km or every 12 months | €70–150 |
| Cabin (pollen) filterClimate | every 15,000 km or every 12 months | €15–40 |
| Brake fluidBrakes | every 24 months | €50–95 |
| A/C service (regas + desiccant)Climate | every 24 months | €70–150 |
| Air filterEngine | every 30,000 km or every 24 months | €15–45 |
| Spark plugsIgnition | every 60,000 km or every 48 months | €50–160 |
| Auxiliary (serpentine) beltEngine | every 120,000 km | €70–180 |
| Coolant replacementCooling | every 150,000 km or every 96 months | €70–150 |
| Manual gearbox oilTransmission | every 150,000 km | €60–130 |
| Front brake padsBrakes | usually at 30,000–60,000 km | €60–150 |
| Front brake discs + padsBrakes | usually at 60,000–120,000 km | €150–320 |
| Rear brake padsBrakes | usually at 50,000–90,000 km | €50–130 |
| Tyres (set of 4)Wheels | usually at 40,000–60,000 km | €320–700 |
| Wiper bladesBody | checked at service | €20–50 |
| 12V batteryElectrical | checked at service | €100–220 |
Roadworthiness tests by mileage
Share of tests in the United Kingdom (DVSA MOT, 2024) that this model failed because of each system. Bold red means more often and green less often than an average car of the same age and mileage. Sample: 6,557 tests.
| thousand km | 50–100 | 100–150 | 150–200 | 200–250 | 250+ |
|---|---|---|---|---|---|
| Brakes | 12.1 % | 14.6 % | 17.4 % | 19.4 % | 19.4 % |
| Suspension | 8.4 % | 13.8 % | 19.3 % | 24.6 % | 23.9 % |
| Steering | 3.4 % | 4.6 % | 8.7 % | 10.0 % | 10.4 % |
| Tyres and wheels | 3.4 % | 7.6 % | 7.3 % | 7.9 % | 7.9 % |
| Lights, wipers and visibility | 20.2 % | 25.6 % | 28.2 % | 31.0 % | 31.9 % |
| Body and corrosion | 5.9 % | 8.5 % | 11.3 % | 12.4 % | 11.7 % |
| Exhaust, emissions and leaks | 2.1 % | 5.1 % | 8.2 % | 8.7 % | 8.8 % |
Owner complaints in the US
Which systems owners reported to the US agency NHTSA and at what mileage. Complaints are not confirmed faults and some relate to recalls. Sample: 216 complaints.
Other generations
Volvo S40 / V50 2004–2012Volvo S60 / V60 I 2010–2018Volvo S60 / V60 II 2018–Volvo S90 / V90 2016–Volvo S80 II 2006–2016Volvo S60 I 2000–2009
Sources and notes
Faults, intervals and prices are indicative and collected from public sources and owner experience; always rely on the service book and a qualified workshop. Test statistics: DVSA – Anonymised MOT tests and results, Open Government Licence v3.0. Owner complaints: NHTSA ODI (public domain). Recalls: DVSA Vehicle Safety Branch Recalls Database, OGL v3.0. Brand and model names are trademarks of their owners and are used only to describe the vehicles.
Updated 07/10/2026