2002 Volvo S40 diesel: common problems and MOT failures

What goes wrong more than usual on a 2002 Volvo S40 diesel?

Parts flagged at MOT more often on the 2002 Volvo S40 diesel than on all cars registered in 2002.

• Engine oil leaks2× usual
  Volvo S40

  32.2% All 2002 cars

  15.8%

  Failed outright at MOT: 0%, against 0.4% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £80–£600 our estimate

  At the viewing: Look under the engine and where the car is usually parked for fresh oil. Ask whether the leak has been looked at.

• Brake discs2.2× usual
  Volvo S40

  27.7% All 2002 cars

  12.7%

  Failed outright at MOT: 2.5%, against 0.9% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £150–£350 our estimate

  At the viewing: Look through the wheel at the brake disc: a deep lip at the edge or heavy scoring means they're worn. Feel for judder when braking.

• Ball joint dust cover3.6× usual
  Volvo S40

  14.9% All 2002 cars

  4.1%

  Failed outright at MOT: 5.4%, against 1.5% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £60–£150 (one joint) ClickMechanic

  At the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.

• Number plate lights2.5× usual
  Volvo S40

  18.3% All 2002 cars

  7.4%

  Failed outright at MOT: 5%, against 1.9% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £5–£40 our estimate

  At the viewing: Check the number plate lights work and the plates are clean and legal.

Common 2002 Volvo S40 diesel MOT failures and advisories

The share of 2002 Volvo S40 diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Brakes
  54% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Suspension
  53% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Lights and electrics
  48% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Tyres
  34% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  33% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Wipers, windscreen and mirrors
  17% of testsRough price £15–£250

  At the viewing: Check for chips in the driver's view, and test the wipers and washers.

Questions to ask the seller before buying a 2002 Volvo S40 diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Any recent work on the engine oil leaks? (Flagged at MOT 2× as often on the 2002 Volvo S40 diesel as on other cars the same age.)
2. Any recent work on the brake discs? (Flagged at MOT 2.2× as often on the 2002 Volvo S40 diesel as on other cars the same age.)
3. Any recent work on the ball joint dust cover? (Flagged at MOT 3.6× as often on the 2002 Volvo S40 diesel as on other cars the same age.)
4. Can I see the service history and receipts for any big jobs?