Volvo V40 D2 (1.6 PSA) — Leaking Fuel Injector Seals
The Volvo D2 uses the PSA 1.6 HDi engine. The copper seals at the base of the injectors fail, allowing exhaust gases to escape. Often termed 'The Black Death'.
Severity
ModerateDIY Difficulty
Hard
Est. Cost
£150–£600
OBD Codes
None
Injectors
Typical layout and location for the Injectors assembly.
Symptoms
- Chuffing or ticking sound matching engine RPM (sounds like a steam train)
- Strong smell of exhaust fumes in the cabin through the vents
- Black, tar-like substance building up around the injectors under the engine cover
Root Cause
The copper washers at the base of the injectors loosen or degrade over time. Carbon-rich exhaust gases escape and bake around the injector body into a solid black tar.
How To Fix
- Catch it early: remove the injector, clean the seat, and fit a new copper washer and guide seal.
- If left too long, the injector will be cemented into the cylinder head by the tar and may require specialist hydraulic pulling equipment to remove without breaking it.
- Cost: £150-300 if caught early, much more if injectors snap.
Estimated Repair Costs
| Repair Option | Est. Cost (GBP) |
|---|---|
| DIY (parts only) | £60–£240 |
| Independent Garage | £150–£600 |
| Main Dealership | £240–£960 |
Other Faults on This Variant
Air Conditioning Condenser Leak (Stone Damage)
MinorThe air conditioning condenser is mounted at the very front of the cooling pack, making it highly susceptible to stone damage from the road, leading to refrigerant loss.
Front Anti-Roll Bar Drop Link Wear
MinorThe front anti-roll bar drop links wear out on heavily potholed UK roads, causing an annoying knocking sound at low speeds.
Alternator / Smart Charge System Failure
SevereModern vehicles use smart charging systems to reduce engine load, but the complex regulators on the alternators frequently fail.
Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.