Volvo XC90
Volvo's first five-cylinder turbodiesel with 2.4-litre common-rail injection. DOHC with 20 valves and Bosch EDC injection. Good torque delivery for comfortable cruising speeds; sensitive to fuel quality at high injection pressure.
Diesel SUV with character
D5 in the XC90 I: plenty of torque for the heavy SUV. Composed on the motorway, no sporting ambitions.
Engine Weaknesses 4
The copper ring seal under the injectors fails to seal properly. Hot exhaust gas escapes, burning oil and forming black soot crusts around the injectors — known as Black Death.
Symptoms: Black soot crusts visible around injectors, diesel/exhaust smell in engine bay, misfires, rough engine running.
Replace timing belt every 160,000 km or 10 years. Water pump is belt-driven — if the old pump blocks after a belt change, the new belt is destroyed immediately. Always replace together.
Symptoms: No warning signal. Missed service or old pump leads to engine damage.
EGR valve becomes clogged with soot particles and carbon deposits. When stuck closed power drops; when stuck open the engine runs rough and smokes.
Symptoms: Power loss, rough idle, increased fuel consumption, black smoke, P0400 fault code.
Hydraulic tappets are sensitive to oil quality. With substandard oil or extended change intervals they start knocking from about 100,000 km.
Symptoms: Ticking noise from valve train after cold start, often disappears after warm-up, in extreme cases permanent.
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.