Volvo XC90
D5 with two-stage sequential turbocharging for 151 kW and immediate response from low RPM. Small turbo for responsiveness, large turbo for high-load work. Complex to maintain due to the two-stage turbo system.
Solid everyday performance
Enough power for relaxed cruising. Not a sports car, but a dependable companion that never gets tired.
Engine Weaknesses 4
On the later D5244T10, injector copper seals can also leak. The two-stage turbocharging system increases cylinder pressure, placing greater stress on sealing surfaces.
Symptoms: Black deposits around injectors, fuel smell, misfires, rough engine running.
The intake manifold swirl flap on the D5244T10 carries the same design problem as in the T4. The plastic linkage fatigues and breaks; loose parts can cause engine damage.
Symptoms: Check engine light, rattling intake noise, power loss, possible engine damage on complete failure.
Replacement interval 160,000 km or 10 years. On the two-stage turbo diesel, engine damage from belt failure is even more costly — so maintenance must not be skipped.
Symptoms: No warning signal. Belt failure leads to immediate engine damage.
DPF on the D5244T10 clogs with frequent urban use. Interrupted regeneration dilutes engine oil with diesel. The two-stage turbo loses efficiency with a sooted intake tract.
Symptoms: DPF warning light, power loss, oil level rises (diesel in oil), increased fuel consumption.
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).