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Known Faults Database

Volvo XC90 problems, reliability and years to avoid

If you are considering buying a used Volvo XC90, these are the common problems worth knowing about first. Our garage database tracks 3 known faults for this model, 2 of them rated high severity. Every one below is a repair bill a seller has good reason not to mention.

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Is the Volvo XC90 reliable?

The Volvo XC90 has 3 known faults in our database, 2 of them rated high severity. The most serious are engine (belt-drive failure on the five-cylinder diesel can wreck the engine) and gearbox (the four speed 4T65E automatic fitted behind the 2.9 T6 has a poor record in the XC90). None of them makes the car a bad buy on its own; the risk is a seller who knows and says nothing.

That is a count of the faults we hold, not a reliability score. Popular cars get written about more, and a newer generation has had less time to show its faults.

Which Volvo XC90 years should you avoid?

No year is a write-off on its own. What matters is which serious faults a given year and engine can have, and whether the car in front of you has had them fixed.

Years and engines with a serious known fault

  • 2001 to 2015, Five-cylinder diesel: 2.4 D5 and 2.4D, plus the D3 and D4 versions of the same engine (2.0 or 2.4) sold until about 2014: belt-drive failure on the five-cylinder diesel can wreck the engine
  • 2002 to 2006, 2.9 T6 (Twin Turbo Petrol): the four speed 4T65E automatic fitted behind the 2.9 T6 has a poor record

Each one is set out in full below, with the symptoms, the typical mileage and a rough repair cost.

Generation 1 of 13 known faults · 12 owner reports · 2 good notes

Volvo XC90 1st Gen (2002 to 2014) problems

Engine/EmissionsHigh severity📝 Editorial

Belt-drive failure on the five-cylinder diesel can wreck the engine. On earlier cars the timing belt tensioners and idler pulleys may give out ahead of the planned belt change and throw the belt, with many failures around 65,000 miles. On S80, V70, XC70 and XC60 builds from 2007 to 2010 the auxiliary belt tensioner was recalled in the UK, because a failed tensioner or belt can get into the timing belt. Owners have had the auxiliary belt snap at 46,790 miles on a 2011 V70 D3, and a newly fitted one come off and wrap round the lower timing belt pulleys on a 50,000-mile 2011 XC60.

Typical symptoms

  • squeal or chirp from the belts, especially from cold
  • battery or power steering warning if the auxiliary belt comes off
  • engine stops suddenly and will not restart

Affected vehicles

Engines:
Five-cylinder diesel: 2.4 D5 and 2.4D, plus the D3 and D4 versions of the same engine (2.0 or 2.4) sold until about 2014
Typical mileage:
46000-65000 miles
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Transmission/ClutchHigh severity💬 Owner reports

The four speed 4T65E automatic fitted behind the 2.9 T6 has a poor record in the XC90, which is heavier and more powerful than the cars the gearbox was designed for, and early failure is widely reported. Coolant getting into the gearbox through a failing transmission oil cooler is one known cause and sticking shift valves are another. Towing without extra oil cooling makes failure more likely. A rebuild or replacement is a big bill on an older car.

Rough guide
£Unknown

Typical symptoms

  • transmission warning message on the dash
  • slipping gears or loss of forward or reverse drive
  • erratic shifting

Affected vehicles

Engines:
2.9 T6 (Twin Turbo Petrol)
Typical mileage:
Unknown miles
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Engine/EmissionsMedium severity📝 Editorial

Fuel injected to burn off the particulate filter can get past the pistons into the sump, so the oil level creeps up and the oil is thinned with diesel. Volvo issued a service bulletin in 2010 for D5 engines with a filter: new engine software to use less fuel during regeneration, and draining the oil back to the middle of the dipstick. A 2010 V70 D3 covering only around 7,300 miles annually needed 0.5 litres of oil taken out after a service warning, and a 2015 V70 D4 had diesel found in its oil after regenerating, with the oil changed free.

Typical symptoms

  • oil level above the maximum mark on the dipstick
  • engine oil that smells of diesel
  • engine service or check warning on the dash

Affected vehicles

Engines:
Diesels with a particulate filter: the five cylinder D5, D3 and D4 (2.4 and 2.0), and the later four cylinder 2.0 D4 (VEA)
Typical mileage:
unknown miles
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What owners report on the 1st Gen

12 single reports, unconfirmed

One owner each, in their own words rewritten as a line, and not counted in our risk scoring. A fault joins the list above once a second report or an editorial source backs it.

  • Electrics · January 2020The remote key springs on a 2014 Volvo XC90 failed, causing the key to dislodge from the ignition and the engine to cut out.
  • Engine · August 2017Inlet manifold swirl flaps on a 2010 Volvo XC90 were renewed in 2015, but failed once more by August 2017, costing an estimated £1,200.
  • Gearbox and clutch · July 2017The automatic gearbox of a 2010 Volvo XC90 began behaving erratically, despite a dealer-recommended flush and refill.
  • Engine · May 2017Inlet manifold swirl flaps on a 2010 Volvo XC90 began to fail, causing operational issues.
  • Engine · April 2016A 2007 Volvo XC90 lost power and entered limp mode in 2014 due to a butterfly valve, costing €1,018.58 to fix.
  • Electrics · March 2016An electronic control module located under the left front passenger floor of an XC90 caused multiple electrical faults when the headlamp flash was activated.
  • Gearbox and clutch · January 2014A Geartronic automatic transmission failed on a 2004 XC90 T6 at 65,000 miles.
  • Gearbox and clutch · November 2013The transfer box of a four-year-old XC90 with 46,000 miles was destroyed at speed on the motorway, costing £2,800 to rebuild.
  • Gearbox and clutch · November 2012Transmission noise was resolved by replacing the transfer box chain housing, which connects the gearbox to the centre differential.
  • Electrics · May 2012Failure of the GPS satellite navigation system can sometimes be remedied by cleaning the CD Rom or DVD disk.
  • Electrics · February 2012A steering lock failure was reported on an XC90, indicating a problem with the vehicle's security system.
  • Gearbox and clutch · October 2010A 2004 Volvo XC90 D5 with 77,000 miles was found to be operating in two-wheel drive only, requiring a new angle gear and connecting sleeve for £1,518.

What owners like about the 1st Gen

2 notes
  • April 2018No Volvo XC90 occupants have died in car-to-car accidents in the UK since 2004, according to official government crash figures.
  • The Volvo XC90 achieved an excellent five-star Euro NCAP crash safety rating, providing strong occupant protection.
Other years0 known faults · 8 owner reports · 7 good notes

Other Volvo XC90 years: owner reports

What owners report

8 single reports, unconfirmed

One owner each, in their own words rewritten as a line, and not counted in our risk scoring. A fault joins the list above once a second report or an editorial source backs it.

  • Electrics · February 2020A Key Tag (Sport Key) for a 2018 Volvo XC90 T8 failed at 22,000 miles, likely due to a flat, non-replaceable battery, costing £220 for a coded replacement.
  • Electrics · August 2019The initial 20-mile fully charged EV range of a 127,000-mile Volvo T8 PHEV disappeared upon starting, with the petrol engine engaging immediately.
  • Brakes · May 2019Brakes on a Volvo XC90 failed on the motorway 200 miles after purchase, with a part found to be missing from assembly.
  • Electrics · November 2018A 2015 Volvo XC90 T8 experienced two complete software failures in three years, resulting in a loss of power.
  • Electrics · September 2018A Volvo XC90 T8 would not travel beyond a few miles in EV mode, even when fully charged, as the petrol engine frequently engaged.
  • Electrics · October 2017A November 2016 Volvo XC90 suffered recurrent low charge 12V battery issues, leading to complete electrical failure within four months of purchase.
  • Electrics · March 2017A leased Volvo XC90 T8 required an ECU replacement within 24 hours of pickup, and later experienced issues with heated seats, navigation, and collision warning sensors.
  • Electrics · July 2016A Volvo XC90 experienced numerous ongoing software problems, with many functions failing or only working temporarily after updates.

What owners like

7 notes
  • The Volvo XC90 offers fantastic ride quality, which is further enhanced by optional air suspension, even with 21-inch wheels.
  • The cabin of the Volvo XC90 is beautifully finished, featuring top-quality materials throughout.
  • The Volvo XC90 is spacious enough for a family and comes equipped with many safety gadgets.
  • The iPad-style infotainment system in the Volvo XC90 is simple to use and visually appealing.
  • The 2015 Volvo XC90 achieved a five-star Euro NCAP rating, with high scores for adult, child, and pedestrian safety, plus safety assist.
  • The Volvo XC90 features excellent adaptive cruise control, enhancing driving comfort and safety.
  • The XC90 T8 has a maximum towing weight of 2,400kg, which is more than adequate for most caravans and other hybrid cars.

Sellers rarely admit these faults outright

We track 9 specific phrases sellers use in adverts to soft-pedal these exact issues. Paste any Volvo XC90 advert and we check it in seconds.

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Volvo XC90 recalls

Recall work is done by the manufacturer, and GOV.UK says you will not usually have to pay for it. These are the 27 DVSA recalls for the XC90, newest first. They do not tell you whether this particular car has had the work: for that, put the registration into the free GOV.UK MOT history check, which shows a recall status where the manufacturer shares it, or ask a franchised dealer to check the VIN.

🏛️ December 2025Cars built March 2016 to September 2025

Front seat belts

On affected vehicles the front left seat bolts may not have been torqued according to specification which could reduce the occupant protection in an impact.

Put right by: Re-torque front seat bolts.

DVSA R/2025/5171 vehicles affected in the UK
🏛️ June 2025Cars built July 2019 to June 2025

BCM2 SW - Safety Notice

Affected vehicles may experience a temporary loss of braking functionality after coasting downhill with 'B' mode selected or when using One Pedal Drive. This could potentially lead to a collision.

Put right by: Install modified software via an Over the Air (OTA) update.

DVSA R/2025/2111,764 vehicles affected in the UK
🏛️ March 2025Cars built April 2019 to November 2021

SPA1 Cell Modules

On affected vehicles the High Voltage (HV) Battery may have a manufacturing defect which could cause the battery cells to overheat when the HV Battery is fully charged. In a worst-case scenario there is a risk of fire when the vehicle is parked up with a fully charged HV Battery.

Put right by: Check and replace the HV Battery if necessary and install modified software.

DVSA R/2025/1172,081 vehicles affected in the UK
🏛️ November 2024Cars built May 2019 to February 2020

BCM2 - Push Road

The rod connecting the brake pedal to the brake booster may not have been assembled correctly. The final torque might not be according to manufacturing specification due to deviations in the equipment. If the rod does disconnect the mechanical connection between brake pedal and brake booster cannot be guaranteed. In the worst-case scenario if the rod disconnects the brake pedal function cannot be guaranteed

Put right by: A Volvo retailer will check and if necessary tighten the rod to correct specification.

DVSA R/2024/4461,028 vehicles affected in the UK
🏛️ March 2024Cars built August 2022 to July 2023

Seat and Seat Belt Torque

The screw joints for the seats and seat-belts may not have been torqued to the correct specification which means in the event of an impact insufficient protection will be available.

Put right by: The solution is to check and adjust the torque.

DVSA R/2024/1244 vehicles affected in the UK
🏛️ December 2023Cars built January 2014 to September 2023

The anchorage bolts for the second-row seat belts and seat belt buckles may not have been correctly secured. In a worst-case scenario this may not provide sufficient protection in the event of a collision.

The anchorage bolts for the second-row seat belts and seat belt buckles may not have been correctly secured. In a worst-case scenario this may not provide sufficient protection in the event of a collision

Put right by: Inspect and re-install.

DVSA R/2023/345572 vehicles affected in the UK
🏛️ January 2023Cars built October 2022 to January 2023

There may be a potential software error in the brake control module.

There may be a potential software error in the brake control module.

Put right by: Update the brake control module software.

DVSA R/2023/02510,197 vehicles affected in the UK
🏛️ October 2022Cars built March 2021 to October 2022

A software error may prevent the engine control module from starting the engine

The Engine Control Module (ECM) may prevent the combustion engine from starting.

Put right by: Download updated software.

DVSA R/2022/3134,755 vehicles affected in the UK
🏛️ October 2021Cars built February 2019 to September 2019

Thrust bearing in turbo charger might not be robust enough

The thrust bearing in the turbo charger may not be robust enough.

Put right by: Replace turbocharger with a modified version which has an improved thrust bearing.

DVSA R/2021/3602,083 vehicles affected in the UK
🏛️ September 2021Cars built May 2019 to November 2020

Potentially insufficient or missing welding connection in the hydraulic unit of the brake system

There may be an insufficient or missing welding connection in the Hydraulic Unit of the Brake System.

Put right by: Replace the Hydraulic Unit.

DVSA R/2021/33128 vehicles affected in the UK
🏛️ June 2021Cars built November 2018 to December 2019

There is a risk that the 15amp fuse could blow which will prevent the low pressure fuel pump from operating

There is a risk that the 15amp fuse could blow which will prevent the low pressure fuel pump operating.

Put right by: Replace the 15A fuse with a 20A fuse which can withstand this peak.

DVSA R/2021/20514,380 vehicles affected in the UK
🏛️ January 2021Cars built September 2020 to September 2020

Vehicles may have the supplementary restraint system control unit incorrectly tightened to the car body

Vehicles may have the Supplementary Restraint System (SRS) control unit incorrectly tightened to the car body.

Put right by: Inspect and tighten the SRS control unit.

DVSA R/2021/001704 vehicles affected in the UK
🏛️ March 2020Cars built January 2019 to March 2020

Software issue means that automatic emergency brake system may not engage

The Automatic Emergency Brake System a function of the IntelliSafe system may not always engage increasing the risk of a collision

Put right by: Affected vehicles must have new software downloaded

DVSA R/2020/07356,385 vehicles affected in the UK
🏛️ December 2019Cars built November 2019 to December 2019

Possible loss of power whilst driving

Possible loss of power whilst driving.

Put right by: Vehicles must have updated software downloaded.

DVSA R/2019/45253 vehicles affected in the UK
🏛️ October 2019Cars built September 2014 to April 2018

The engine's plastic inlet manifold may melt and deform

The engines plastic inlet manifold may melt and deform

Put right by: Update vehicles with improved soot reducing software cleaning of TMAP and EMAP. Fit additional hoses where necessary.

DVSA R/2019/180
🏛️ April 2019Cars built April 2014 to May 2019

An engine cooling system hose may break

An engine cooling system hose may break and could cause a coolant leak.

Put right by: Replace the hose on affected vehicles.

DVSA R/2019/128959 vehicles affected in the UK
🏛️ January 2019Cars built April 2015 to May 2016

Small cracks on the inside of a rubber fuel hose

Small cracks on the inside of a rubber fuel hose.

Put right by: Replacement of affected fuel hoses.

DVSA R/2018/37730,777 vehicles affected in the UK
🏛️ November 2018Cars built May 2016 to October 2018

Possible software issue in the vehicle connectivity module (VCM)

There may be a software issue in the Vehicle Connectivity Module.

Put right by: Upgrade software in the Vehicle Connectivity Module.

DVSA R/2018/3147,322 vehicles affected in the UK
🏛️ June 2017Cars built September 2016 to November 2016

Rear passenger seat belt pre tensioner may not be to specification

The pre-tensioner in the drivers side third row passenger seat belt may not have been produced according to the correct specification In the event of a collision the pre tensioner and seat belt will still operate as intended but a very small part could enter the passenger compartment. As a temporary measure until the seat belt has been replaced it is recommended that the seat belt is not used.

Put right by: On affected vehicles replace the seat belt.

DVSA R/2017/188501 vehicles affected in the UK
🏛️ March 2017Cars built November 2016 to March 2017

Retaining bolt for inflatable curtain may be broken

The retaining bolts used to assemble the Inflatable Curtain may be broken and offer less protection in the event of an incident.

Put right by: On affected vehicles replace all retaining bolts.

DVSA R/2017/1052,409 vehicles affected in the UK
🏛️ January 2017Cars built August 2016 to September 2016

One or more airbags may fail to deploy in the event of a collision

It has been identified by the manufacturer that the air-bag initiator does not meet specification. This can therefore result in the initiator not functioning correctly which can lead to none deployment of the air-bag. Should a collision occur then there is an increased risk of injury to the occupants of the vehicle.

Put right by: Recall all affected vehicles to replace the air-bags with a new quality assured component.

DVSA R/2017/0021,415 vehicles affected in the UK
🏛️ November 2016Cars built February 2015 to August 2016

Seatbelt may separate from the buckle

It has been identified there is a possibility the front seatbelt buckle stud may not have been punched correctly during production. This may result in a separation between the buckle and seatbelt bracket if the vehicle is involved in a collision.

Put right by: Recall all affected vehicles to inspect the seatbelt buckle and if required to replace the seatbelt buckle.

DVSA R/2016/25747 vehicles affected in the UK
🏛️ October 2015Cars built August 2015 to September 2015

Engine may fail

Affected vehicles may have a crankshaft that has been insufficiently hardened which may fail and nay cause engine failure.

Put right by: Check identity of crankshaft. If the relevant marking is not present then replace engine.

DVSA R/2015/2059 vehicles affected in the UK
🏛️ August 2015Cars built January 2015 to July 2015

Third row passenger airbags may fail to deploy as intended

Affected vehicles have interior panels that may prevent the inflatable curtain airbags from deploying as intended. This could reduce the level of protection offered to third row passengers in the event of an accident.

Put right by: Modify affected interior panels to allow the inflatable curtains to deploy as intended.

DVSA R/2015/1741,690 vehicles affected in the UK
🏛️ July 2015Cars built September 2008 to October 2009

Loss of steering assistance

A hose for the power steering assistance hydraulics could come into contact with the cooling fan. This would cause a noise which an observant driver may be able to hear. If the hose and fan conflict for long enough then it is possible for the hose to leak power steering fluid to the degree that servo assistance could be lost.

Put right by: Recall the vehicles that are likely to be affected and check the hydraulic hose for damage and relace as necessary. The hose will then be secured with a modified bracket.

DVSA R/2015/1402,584 vehicles affected in the UK
🏛️ June 2015Cars built January 2015 to May 2015

Sips system may not deploy when required

It has been identified that the wiring harness for the Side Impact Protection System airbag (SIPS) on the drivers and passengers front seats may have been routed incorrectly. This could result in the wiring harness becoming damaged which will illuminate the Supplemental Restraint System (SRS) light on the instrument panel. If the SRS light is illuminated then additional care should be taken when driving the vehicle as SRS functions may be affected.

Put right by: Recall all affected vehicles to check the routing of the wiring harness and if required reroute it and repair any damage.

DVSA R/2015/111301 vehicles affected in the UK
🏛️ April 2012

Engine may fail

There could be a sudden and unexpected failure of the bottom end of the engine because of a non-conformity during production of the connecting rods.

Put right by: Recall the vehicles that are likely to be affected to replace the engine.

DVSA R/2012/0566 vehicles affected in the UK

Recall data published by the Driver and Vehicle Standards Agency under the Open Government Licence v3.0. A recall listed here may not apply to every car of this model: the build dates and the registration check are what decide it.

Volvo XC90 cambelt, and service intervals

An overdue cambelt is the most expensive thing a seller can fail to mention on a used XC90. These are the figures UK specialists work to.

Timing belt (cambelt)Belt
2.0 D4, D4204T
90,000 miles or 10 years, whichever comes first

Volvo VEA 4-cylinder engines have a timing belt interval of 90,000 miles or 10 years (whichever comes first). The auxiliary belt and tensioner must also be checked or replaced simultaneously.

Timing belt (cambelt)Belt
2.4 D5, D5
96,000 miles or 8 years, whichever comes first

Volvo's scheduled change for the five-cylinder diesel was 96,000 miles or 8 years on earlier cars; later cars are commonly quoted at 108,000 miles or 10 years, and the shorter scheduled figure is used here. Tensioners and idler pulleys can fail before the scheduled change and throw the belt, and one widely repeated recommendation is to renew the timing belt, tensioner, pulleys and water pump at 60,000 miles or 4 years. Also check when the auxiliary belt and tensioner were changed: on 2007 to 2010 V70 builds that tensioner was recalled in the UK because a failed belt can foul the timing belt.

Always confirm against the vehicle handbook. Intervals vary by engine, and several manufacturers revised theirs after failures in service.

Repair costs are typical UK ranges, not quotes. Actual cost depends on condition and garage.Data last verified: October 2026

Volvo XC90 buying questions

What are the most common Volvo XC90 problems?

Three stand out. Engine: belt-drive failure on the five-cylinder diesel can wreck the engine (typically 46000 to 65000 miles). Gearbox: the four speed 4T65E automatic fitted behind the 2.9 T6 has a poor record in the XC90. Engine: fuel injected to burn off the particulate filter can get past the pistons into the sump. The full list above is grouped by generation, with typical mileage and a rough repair cost for each.

Which Volvo XC90 years should I avoid?

No Volvo XC90 year is a write-off, but the 1st Gen (2002 to 2014) carries the most serious faults: engine and gearbox. Year matters less than whether the specific car has had the known fixes, so check the history for them.

What should I check when viewing a used Volvo XC90?

Ask the seller about the engine and gearbox faults on this page and whether they have been fixed, with invoices. On the test drive watch for squeal or chirp from the belts, especially from cold, transmission warning message on the dash and oil level above the maximum mark on the dipstick. Read the MOT history for repeat advisories, then paste the advert into the free check, which reads it against all 3 known faults before you travel. Check a Volvo XC90 advert →

Are there any recalls on the Volvo XC90?

The DVSA lists 27 safety recalls for the Volvo XC90 issued between 2012 and 2025. The most recent, from December 2025, is "Front seat belts". Recall work is done by the manufacturer, and GOV.UK says you will not usually have to pay for it. This list is by model, so it cannot tell you whether one particular car has had the work: the free GOV.UK MOT history check shows a recall status from the registration where the manufacturer shares it, and a franchised dealer can check the VIN.

What is the real MPG of a Volvo XC90?

Owners report 31.8 mpg on average across the Volvo XC90 engines with data, about 82% of the official combined figure. The gap between official and real-world economy varies a lot by engine, so the Real MPG page lists every engine and generation separately, from 859 owner submissions. Volvo XC90 Real MPG by engine →

Looking at a Volvo XC90 right now? Check the advert before you go and see it.

Where this Volvo XC90 fault data comes from

If you used to check the Honest John “Good & Bad” section before the site closed in 2026, this page is where that information now lives. We rebuilt the Volvo XC90 owner-report history from the archived Honest John dataset, added our own research, specialist and owner-club sources and DVSA recall data, and we keep it free. Each fault above is badged with its source. The same data feeds our free advert check, which reads a listing against every known fault for the exact engine and year.

CarAdCheck is not affiliated with Honest John or Volkswagen Financial Services. What happened to Honest John, and where each feature lives now.

Before you go and see it

Knowing what a Volvo XC90 goes wrong with is half of it. The rest is reading the advert and checking the car's history before you hand any money over.

How to haggle for a used car: negotiate the price with what its records show13 min readHPI check vs carVertical: which is better, and our pick for a UK car9 min readMOT advisories explained: how to check them, and which ones should worry you12 min read
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