Stylish, safe and a brilliant all-rounder
A former What Car? Car of the Year and Used Car of the Year, the XC40 combines Scandinavian design, top-tier safety and genuine premium quality at prices below German rivals. Huge used supply means buyers can afford to be very selective.
We track 7 known issues across the Volvo XC40 range, including 1 rated as safety-critical. Knowing which variants and configurations to approach with caution can save you from expensive surprises after purchase.
Found a Volvo XC40? Enter the reg to see which of our 7 known issues apply to that exact car, plus full MOT history and mileage checks.
XA40 (2017–2023) — Petrol options included the 1.5 T3, 2.0 T4, with 2.0 D4 on the diesel side.
The XC40 shows a documented pattern of suspension component failures at dramatically higher rates than the fleet average, with MOT data showing failure rates up to 43.2 times the national average on 2.0-litre variants. The most commonly affected components are front lower control arms and anti-roll bar links, which can fracture without warning. This affects all engine variants but is most severe on the heavier 2.0-litre models. The issue appears to be design-related rather than manufacturing quality, with failures occurring relatively early in the vehicle's life.
Suspension component fracture creates an immediate safety risk with potential for loss of vehicle control, particularly during emergency manoeuvres or cornering. A fractured control arm can cause sudden wheel misalignment or complete loss of steering control. Repair typically requires replacement of the affected component plus wheel alignment, costing £300-800 depending on which component has failed.
Listen for knocking, clunking or rattling over bumps during the test drive. Inspect the underside for corroded or cracked suspension components. Check the MOT history for suspension-related advisories, which often predict future failures.
The 2.0-litre D4 diesel engine in the XC40 suffers from diesel particulate filter (DPF) blockage issues typical of modern diesel engines used primarily for urban driving. The compact SUV nature of the XC40 means many are used for school runs and shopping trips rather than motorway driving, preventing the high exhaust temperatures needed for passive DPF regeneration. This leads to progressive filter blockage and eventual failure. The issue is compounded by the relatively small DPF size fitted to meet packaging constraints in the compact platform.
A completely blocked DPF will put the vehicle into limp mode with severely reduced power and may prevent starting if left untreated. Professional DPF cleaning costs £200-400, while replacement units cost £1200-1500 fitted. The vehicle remains driveable with minor blockage but should not be used for long journeys until repaired to prevent complete system failure.
Ask about the car's typical usage — short urban journeys prevent DPF regeneration. Check for DPF warning lights and ask about any previous regeneration issues. A forced regeneration at a garage costs far less than a DPF replacement.
The XC40 demonstrates significantly accelerated brake disc wear compared to the fleet average, with MOT data showing failure rates up to 2.7 times higher than typical. This affects all engine variants and appears to be related to the vehicle's weight distribution and brake system design. The front discs are particularly prone to excessive wear and warping, requiring replacement earlier than expected for a vehicle in this class. The pattern suggests the brake disc specification may be undersized for the vehicle's kerb weight and typical usage.
Severely worn brake discs reduce stopping performance and can lead to brake fade or complete brake failure in extreme cases. Warped discs cause vibration and uneven pad wear, reducing overall braking effectiveness. Replacement typically requires both discs and pads per axle, costing £300-600 for front axle or £250-500 for rear axle depending on specification.
Check brake disc condition for lipping or scoring. Test braking at moderate speed for pulling to one side or vibration through the steering wheel. Review MOT advisories for brake-related items.
This excessive wear rate affects all engine variants and mileage bands, suggesting a systemic issue with brake system sizing or pad compound selection. The pattern indicates the brake pads may be too soft or the brake system may be working harder than optimal due to the vehicle's weight and braking characteristics. This issue directly correlates with the accelerated brake disc wear also seen on this model.
Brake pads worn below 1.5mm thickness will fail the MOT and create a safety risk. Completely worn pads will damage the brake discs requiring more expensive repairs. Pad replacement typically costs £150-300 per axle but if discs are damaged the total cost rises to £400-800 per axle. The vehicle should not be driven with severely worn brake pads.
Check brake disc condition for lipping or scoring. Test braking at moderate speed for pulling to one side or vibration through the steering wheel. Review MOT advisories for brake-related items.
The 2.0-litre D4 diesel engine shows a pattern of malfunction indicator lamp (MIL) illumination at 25.5 times the fleet average rate. This typically indicates emissions system faults, most commonly related to the exhaust gas recirculation (EGR) system, DPF sensors, or NOx sensor failures. The issue appears concentrated in the 20-40k mile range, suggesting component degradation rather than manufacturing defects. While not immediately dangerous, the MIL indicates actual emissions system problems that will worsen if left untreated.
An illuminated MIL indicates active emissions system faults that will cause MOT failure and potentially lead to more serious engine problems if ignored. Common repairs include EGR valve cleaning or replacement (£300-600), NOx sensor replacement (£400-700), or DPF system repairs (£500-1500). The vehicle remains safe to drive but should be diagnosed promptly to prevent escalation.
Check all electrical functions systematically: windows, mirrors, lights, infotainment, heated seats, air conditioning. Look for any warning lights on the dashboard. A diagnostic scan before purchase can reveal stored fault codes.
For the full breakdown of all 7 tracked issues with repair costs, see the Volvo XC40 common problems page.
Based on 161k real DVSA MOT tests, the Volvo XC40 fails more often than average on several items. The biggest outlier is anti-roll bar links worn at 23x the fleet average, followed by headlight fault (14x).
When viewing a specific car, check its MOT history for recurring advisories in these categories. See the full Volvo XC40 MOT failure breakdown for data at every mileage point.
Routine servicing (oil and filter change every 18k miles) typically costs £120–£180 at an independent garage.
See the full Volvo XC40 service schedule for every interval and cost breakdown.
The Volvo XC40 has some well-documented weak points, including 1 safety-critical issue that demand careful checking. The right example, properly maintained, can still be a sound purchase — but cutting corners on the pre-purchase inspection is not advisable. 2020-2023 models benefit from the most refined software and widest powertrain choice. Avoid early 2018 cars where infotainment teething issues were most common.
Before committing, check the car's full MOT history, verify the service record is complete, and if possible arrange a specialist inspection. Enter any registration into our free report to see the complete picture.
Get Car Wise maintains a database of known mechanical issues for every popular car on UK roads, tracking the faults that owners, specialists and DVSA data reveal.
When you run a report on a specific Volvo XC40, we cross-reference the exact variant, engine and age against our database of 7 known issues. Combined with full MOT history analysis, mileage verification and DVLA data, you get a complete picture before viewing.
Enter the registration for MOT history, mileage verification, known faults for that exact variant, and a Get Car Wise Score.
This guide was compiled from independent expert reviews, DVSA MOT data, specialist workshops and our own database of 7 known Volvo XC40 issues. We are not affiliated with any source listed.