Ti-VCT cam phasers / oil control valve
usually 80,000–180,000 km · Medium risk
engine codes: HWDA, HXDA, HXDB, PNDA, PNDB, IQDB
Signs: Rattle on start, rough idle, VCT codes (1.6 Ti-VCT)
Fix: Replace phasers / solenoid; correct oil
€300–800
Common faults, service intervals and costs
Volvo S40 / V50
2004–2012
5
engines covered
17
known faults
45,984
roadworthiness tests in the statistics
25
official recalls
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
The Volvo S40 / V50 was built from 2004 to 2012.
For this generation we cover 5 engines and 17 known faults, each with the mileage range where it usually appears.
The most expensive known risk is Turbo failure (oil starvation, 16v): it usually appears at 80,000–200,000 km and costs €700–1,600 to fix.
In UK roadworthiness tests in 2024, at 150–200 thousand km this model most often failed on: lights, wipers and visibility (21.3 %), suspension (19.6 %), brakes (10.1 %). It fails less often than average on: exhaust, emissions and leaks.
Engines
| Engine | Fuel | Timing drive | Oil |
|---|---|---|---|
| 1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma) | Petrol | Belt · 150,000 km / every 120 mo | 5W-20 / 5W-30 · Ford WSS-M2C913-C / 948-B · ~3.8–4.1 L · every 15,000 km |
| 1.3–2.5 MZR / Duratec HE petrol | Petrol | Chain | 5W-30 · API SL/SM / Ford WSS-M2C913 · ~4.3 L · every 15,000 km |
| 1.6 HDi / TDCi / e-HDi (DV6, 8v / 16v) | Diesel | Belt · 150,000 km / every 96 mo | 5W-30 · PSA B71 2290 / Ford WSS-M2C913-C · ~3.75 L · every 15,000 km |
| 2.0 HDi / TDCi / BlueHDi (DW10) | Diesel | Belt · 150,000 km / every 96 mo | 5W-30 · PSA B71 2290 / Ford WSS-M2C913-C / 934-B · ~4.25–5.5 L · every 15,000 km |
| 2.0 / 2.4 D / D3 / D4 / D5 5-cyl (Volvo D5) | Diesel | Belt · 120,000 km / every 96 mo | 5W-30 / 0W-30 · ACEA A5/B5 / C2 · ~6.0 L · every 15,000 km |
Faults by engine
1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma)
Ignition coil pack
usually 80,000–160,000 km · Wear part
Signs: Misfire
Fix: Replace coil
€80–200
Thermostat housing leak (plastic)
usually 80,000–160,000 km · Wear part
Signs: Coolant loss
Fix: Replace housing
€100–250
Valve clearance (shims)
usually 150,000–250,000 km · Wear part
Signs: Ticking; check more often on LPG
Fix: Adjust clearances
€150–400
1.3–2.5 MZR / Duratec HE petrol
Ignition coils / throttle body
usually 100,000–180,000 km · Wear part
Signs: Misfire, uneven idle
Fix: Replace coil, clean throttle body
€100–300
1.6 HDi / TDCi / e-HDi (DV6, 8v / 16v)
Turbo failure (oil starvation, 16v)
usually 80,000–200,000 km · High risk
model years 2004–2011 only
Signs: Whistle, blue smoke, oil loss — carbon blocks the oil feed filter
Fix: Replace turbo, oil feed pipe with filter, clean the sump
€700–1,600
Injector copper seal leak → carbon build-up
usually 80,000–200,000 km · High risk
Signs: Ticking, diesel / soot smell, carbon around injectors
Fix: Replace seals early; remove carbon
€200–900
EGR valve / cooler
usually 100,000–200,000 km · Medium risk
Signs: Limp mode, power loss
Fix: Clean or replace
€200–600
2.0 HDi / TDCi / BlueHDi (DW10)
Injectors / injector seals
usually 150,000–250,000 km · Medium risk
Signs: Smoke, knocking, hard start
Fix: Replace seals / injectors
€300–1,500
EGR valve / swirl flap actuator
usually 120,000–220,000 km · Medium risk
Signs: Limp mode
Fix: Clean or replace
€200–700
Turbo actuator / vanes
usually 150,000–250,000 km · Medium risk
Signs: Overboost / underboost
Fix: Clean or replace
€300–1,000
2.0 / 2.4 D / D3 / D4 / D5 5-cyl (Volvo D5)
Swirl flaps / intake manifold (pre-2007)
usually 120,000–220,000 km · Medium risk
model years 2001–2007 only
Signs: Engine light, power loss
Fix: Replace manifold / actuator
€400–1,000
EGR valve / cooler
usually 120,000–220,000 km · Medium risk
Signs: Limp mode
Fix: Clean or replace
€300–900
Crankcase breather (oil trap) clogging
usually 150,000–250,000 km · Medium risk
Signs: Oil leaks from seals, crankcase pressure
Fix: Replace oil trap / breather
€150–400
Turbo actuator
usually 150,000–250,000 km · Medium risk
Signs: Limp mode
Fix: Replace actuator
€300–800
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
PowerShift MPS6 (wet, Getrag)
MPS6 fluid & clutch wear
usually 120,000–220,000 km · Wear part
Signs: Rough shifts when the fluid is old
Fix: Fluid change every 60,000 km
€200–1,500
Scheduled service
Intervals and typical prices for the 1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma) 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 |
| Timing belt kit + water pumpEngine | every 150,000 km or every 120 months | €450–900 |
| 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: 45,984 tests.
| thousand km | 0–50 | 50–100 | 100–150 | 150–200 | 200–250 | 250+ |
|---|---|---|---|---|---|---|
| Brakes | 3.7 % | 6.6 % | 8.1 % | 10.1 % | 11.7 % | 13.3 % |
| Suspension | 4.7 % | 8.8 % | 14.3 % | 19.6 % | 22.8 % | 23.8 % |
| Steering | 1.2 % | 2.7 % | 3.1 % | 4.1 % | 5.1 % | 5.9 % |
| Tyres and wheels | 4.4 % | 6.4 % | 8.1 % | 10.1 % | 11.8 % | 12.9 % |
| Lights, wipers and visibility | 8.6 % | 13.3 % | 17.8 % | 21.3 % | 23.9 % | 25.9 % |
| Body and corrosion | 1.2 % | 2.9 % | 5.7 % | 8.7 % | 10.3 % | 11.7 % |
| Exhaust, emissions and leaks | 1.2 % | 1.8 % | 3.9 % | 5.2 % | 5.7 % | 6.2 % |
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: 275 complaints.
Official recalls
Recalls the manufacturer published in the United Kingdom for this model (25). The same recalls usually apply across Europe. Ask an authorised dealer to check by VIN whether your car is affected and whether the work has been done.
- Other Exhaust sleeve may detach23/12/2013 · R/2013/156
- Suspension / axles Loss of drive08/04/2013 · R/2013/046
- Fire risk Fluid may leak into wiring harness which may cause fire01/12/2011 · R/2011/163
- Engine / loss of power Clutch pedal mechanism may fail07/09/2011 · R/2011/127
- Brakes / ABS / ESP Brakes may not perform as expected28/06/2011 · R/2011/075
- Steering Support member may crack23/03/2011 · R/2011/031
- Fire risk Fire may occur18/02/2011 · R/2011/019
- Wheels / tyres Passenger seat may not be fitted correctly22/12/2010 · R/2010/233
The other recalls (17) are listed in the app.
Other generations
Volvo S60 / V60 I 2010–2018Volvo S60 / V60 II 2018–Volvo S90 / V90 2016–Volvo S80 II 2006–2016Volvo S40 / V40 I 1995–2004Volvo 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