Volvo XC90
Upgraded D5 generation with 136 kW and increased injection pressure for improved torque of 450 Nm. Variable turbine geometry for improved response. Reliable with regular oil care; check the particulate filter on later versions.
SUV with diesel dignity
D5 in the large XC90: adequate power for 7 seats. Relaxed on the motorway, no sports pretence.
Engine Weaknesses 5
The copper seal under the piezo injectors no longer seals properly. Combustion gases escape, burn the engine oil, and form black carbon crusts around the injectors — costly problem on the D5244T4.
Symptoms: Black crusts around injectors, soot smell in engine bay, misfires, power loss, increased fuel consumption.
The plastic swirl flap linkage in the intake manifold fatigues and breaks. Loose parts can be sucked into the combustion chamber and damage valves or pistons. Damage up to €5,000 possible.
Symptoms: Check engine light, power loss, rattling noise from intake area, in worst case engine damage.
Replace timing belt every 160,000 km or 10 years. Water pump must be changed at the same time without exception. New belt with old pump is a frequent cause of immediate consequential damage.
Symptoms: No warning. Belt failure leads to total damage with bent valves.
EGR valve and EGR cooler become contaminated with soot particles and carbon deposits. A stuck valve causes power loss and elevated emissions. EGR cooler leakage can introduce water into the intake tract.
Symptoms: Power loss, rough idle, black smoke, P0400 fault codes, increased fuel consumption.
DPF clogs with frequent short-trip use as regeneration temperature is not reached. Interrupted regeneration cycles contaminate engine oil with diesel and raise the oil level.
Symptoms: DPF warning light, power loss, increased fuel consumption, engine oil smells of diesel, oil level rises.
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).