Volvo XC90
Upgraded version of the five-cylinder naturally-aspirated engine with 125 kW and intake VVT. Same robust chain drive construction as the B5244S, but with more power from a revised intake system. Well suited to relaxed long-distance driving.
Smooth naturally aspirated
Naturally aspirated five-cylinder with a pleasant exhaust note and adequate power for relaxed touring. No turbo needed.
Engine Weaknesses 4
The timing belt also drives the water pump. Belt failure or skipping causes immediate engine damage. Replacement interval 160,000 km or 10 years including water pump.
Symptoms: No warning before belt breaks. Sudden stall or loud rattling signals damage.
The plastic PCV oil separator housing becomes brittle and clogs internally with sludge. Elevated crankcase pressure forces oil past seals — typical Volvo five-cylinder problem.
Symptoms: Rough idle, whistling noise, oil mist from breather hoses, oil spots under the vehicle.
The B5244S2 naturally-aspirated engine shows cooling system weaknesses at high mileage: water pump and radiator can leak or fail. Water pump is part of the timing belt service kit; replace radiator immediately on any leak.
Symptoms: Coolant loss, engine temperature rises in city traffic, slight streaking visible on radiator.
The B5244S2 valve cover gasket gives out at higher mileage and loses oil. The oil burns on hot exhaust components and produces a characteristic smell. Inexpensive and straightforward repair, but should be done promptly.
Symptoms: Oil smell after driving, smoke cloud after extended driving, oil film visible on top of engine.
Vehicle Weaknesses 7
The Aisin Warner AW55-50/51SN gearbox in the XC90 I is regarded as its biggest weakness: from 100,000 km it shifts harshly and with unusually long gear-change intervals. Valve body faults often require a complete transmission overhaul.
The Haldex all-wheel drive system on early XC90 models (pre-2007) shows wear at the coupling and differential. If the damage is not corrected, the entire drivetrain can fail.
The optional air suspension compressor on the XC90 I overheats or freezes in sub-zero temperatures. Moisture in the compressor and pipes freezes at around -5°C and blows the fuse. Repair at the dealer around €1,600.
On the XC90 I, tie rod ends (especially outer), ball joints and control arms at the front axle wear out. This leads to wheel misalignment and heavy one-sided tyre wear. Replace early to avoid consequential damage.
The front subframe behind the radiator is known for corrosion, especially on vehicles from road-salt regions. Visible rust on the subframe requires treatment and sealing (€600+).
The nav and audio system of the XC90 I fails due to cold solder joints in the RTI control unit — a known Volvo issue of this era. Replacement units cost over €700; professional re-soldering is cheaper.
Rear control arm bushings deteriorate after approximately 150,000 km. Knocking over bumps and unstable handling are the result. Replacement costs €500–900.
Reports & Tests
957 owner complaints filed with NHTSA (2002–2014). Most reported: Electrical (276), Powertrain (275), Engine (85).