Volvo S90
D4 four-cylinder diesel with 140 kW and twin-turbocharging for strong torque of 400 Nm. Euro 6 compliant with SCR catalyst and common-rail injection at up to 2,000 bar injection pressure. Robust base with known particulate filter issues with frequent short-trip use.
Stronger diesel for the saloon
D5 VEA in the S90: refined diesel with adequate thrust. Touring diesel for the premium class.
Engine Weaknesses 7
The D4 190 hp VEA diesel was also affected by the 2020 EGR cooler recall. Clogged EGR systems with fire risk occurred on vehicles with the D4204T14 engine just as on the weaker D3. Check recall status.
Symptoms: Check engine light, engine throttling, in severe cases smoke from engine bay
The D4 Drive-E turbocharger shows turbine wheel damage from 80,000–120,000 km. Debris can contaminate the intercooler. Primary cause: frequent short trips and overdue oil changes.
Symptoms: Sudden power loss, black smoke, metallic whistling or grinding from engine bay, check engine light
On the D4 variant, the elevated EGR soot input also leads to accelerated DPF clogging. The combined EGR+DPF problem makes diagnosis difficult. A predominantly short-trip driving profile worsens both issues.
Symptoms: DPF warning light, engine power reduction, increased fuel consumption, occasionally rough running
The high-pressure common-rail injectors of the 190 hp D4 diesel are more susceptible to wear than those of the weaker D3, because the higher injection pressure places greater stress on precision components.
Symptoms: Rough engine running, hard starting, knocking at idle, fuel dripping at injector
The D4 Drive-E EGR cooler is prone to sludge build-up from overcooling. According to a Pistonheads forum thread, a Volvo service manager confirmed this as a known problem with this engine. Repair cost approx. 700 GBP.
Symptoms: Check engine light (EGR fault code), idle fluctuations, reduced fuel consumption after repair (from 50 to 38 mpg), occasional limp mode
DPF problems from short-trip use are common on the D4. Complete DPF regeneration requires extended motorway driving. Some vehicles need recall replacement of the particulate filter, intake tract and EGR.
Symptoms: DPF warning light, power reduction, elevated oil level from fuel entry during active regeneration attempts
Rubber hoses between the turbocharger and intercooler split over time, especially the hose on the turbine side. Typical problem commonly diagnosed first in forums. A DIY fix is possible.
Symptoms: Sudden power loss, hissing under load, check engine light P0299
Vehicle Weaknesses 10
A faulty weld between the rotor shaft and the hydraulic brake assembly was found on the V90 II and S90 II. If it fails, ABS, ESC and brake assist are disabled. Volvo issued a recall in 2021.
On XC60 II vehicles built between September 2018 and April 2019, nuts and bolts at the rear axle may be too loose. Handling can change abruptly; check recall status.
Plastic intake manifolds on diesel engines up to model year 2018 can overheat and pose a fire risk. Check for Volvo recall; affected models were fitted with metal manifolds.
Water gets into the windscreen wiper motor and causes it to fail. SPA platform models are affected; a 2020 recall addressed incorrectly tightened wiper arms. Visibility in rain significantly impaired.
The air suspension elements on the V90 Cross Country models show wear from as early as 70,000–100,000 km. A warning message and loss of ride comfort announce the failure; repair costs are substantial.
The Sensus infotainment system on the SPA platform (XC60 II, S90 II, V90 II, S60 III, V60 II) freezes or reboots while driving. Software updates improve stability. Steering wheel controls drop out sporadically.
The optional panoramic roof on the V90 II and S90 II shows malfunctions when opening/closing automatically. Faulty sensors or motor controllers can be expensive; water ingress possible if the seal is damaged.
The Sensus infotainment freezes or goes black and does not respond to touch. Smartphone connectivity problems are common; software updates usually help.
Bodywork issues are the most commonly reported weak point by S90 and V90 owners in reliability surveys (8.5%). These usually involve minor paint damage and localised rust spots.
Rear brake pads on the V90 II wear unevenly and generate heavy brake dust. The cause is the electric parking brake and automatic braking functions.