Volvo XC90
Evolved 3.2-litre naturally-aspirated engine with reduced internal friction and 179 kW. Improved crankshaft bearing and revised thermal management. Manufactured at the Ford plant in Wales; check chain tensioner above 150,000 km.
7-seater without urgency
3.2 naturally aspirated engine in the big SUV — adequate for family duties, no sport mode needed or available.
Engine Weaknesses 4
B6324S5 camshaft end plugs can leak oil — same TSB issue as the predecessor. Volvo has issued a repair procedure (TNN21-28).
Symptoms: Oil seeping from the side of the cylinder head, oil smell after driving, gradual oil loss.
The B6324S5 uses a diaphragm for PCV regulation. When the diaphragm fails, full intake vacuum acts on the crankcase: oil is actively drawn into the intake tract. A functioning PCV system shows slight negative pressure at idle.
Symptoms: Oil consumption with no visible leaks, oil in air filter element, rough idle, whistling noise.
Even the revised B6324S5 shows slight to moderate oil consumption at higher mileages. Up to 0.5 L per 1,000 km is internally tolerated by Volvo, but should be monitored.
Symptoms: Oil level visibly drops between oil changes, no smoke or leaks detectable.
The six-cylinder in the XC90 regularly needs new engine mounts from about 120,000 km. Thermostat and coolant circuit are under greater load in this heavy SUV. Check thermostat proactively at coolant changes.
Symptoms: Vibrations at idle and under load, engine rocking, temperature rise in city traffic.
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).