Skip to content
KickTyres
MajorVery commonEngine

Volvo XC60: Oil Separator (PCV) Failure — B4204T / B6304T

Oil Separator (PCV) Failure — B4204T / B6304T is a very common engine fault on the Volvo XC60 on the 2010–2017 cars, and we rate it major. Putting it right costs $350 to $1,100 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 20 documented faults on the Volvo XC60.

Vehicle
Volvo XC60
Engine
2.0L / 3.0L
Years
2010–2017
Fuel
petrol
System
Engine

This page covers the Volvo XC60 as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Volvo XC60 faults20 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the PCV / oil separator yet. We would rather show none than show a picture of a different part.

What goes wrong

The same crankcase ventilation oil separator failure that affects the XC90 B6xxx engines also afflicts the B4204T 2.0T and B6304T 3.0T petrol engines in the XC60. Sludge blockage causes crankcase pressure to spike, forcing oil past seals into the intake tract. Left unaddressed, the turbocharger oil return line also backs up, promoting turbo bearing failure. The separator is an inexpensive part but labour-intensive to access on the 3.0T.

What you would notice

  • Blue smoke under deceleration or cold start
  • Elevated oil consumption between services
  • Oily residue inside intercooler piping
  • Rough idle with engine oil smell in cabin or engine bay

How to check it

Where to look. Engine crankcase ventilation system, varies by engine side

Inspect all PCV hoses for cracks and oil weeping at connection points. Verify the air filter box for any oil misting. At idle remove the oil filler cap and feel for positive crankcase pressure blowing out — this confirms separator blockage. If a workshop inspection is possible: Remove the intercooler outlet hose and check for oily deposits inside.

Parts involved: PCV / oil separator.

What it costs to put right

$350 to $1,100 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

  • “Has the oil separator or PCV system been replaced?”
  • “What is the approximate oil use between services?”
  • “Has the vehicle ever consumed excessive oil or produced blue smoke?”

Now check the Volvo XC60 you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Volvo XC60 buyer questions

Is oil separator (pcv) failure — b4204t / b6304t serious on a Volvo XC60?

We rate it major and very common on the Volvo XC60. The same crankcase ventilation oil separator failure that affects the XC90 B6xxx engines also afflicts the B4204T 2.0T and B6304T 3.0T petrol engines in the XC60. Sludge blockage causes crankcase pressure to spike, forcing oil past seals into the intake tract. Left unaddressed, the turbocharger oil return line also backs up, promoting turbo bearing failure. The separator is an inexpensive part but labour-intensive to access on the 3.0T.

How much does it cost to fix on a Volvo XC60?

$350 to $1,100 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Volvo XC60 years are affected?

Our research records this fault on the 2010–2017 Volvo XC60. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Inspect all PCV hoses for cracks and oil weeping at connection points. Verify the air filter box for any oil misting. At idle remove the oil filler cap and feel for positive crankcase pressure blowing out — this confirms separator blockage. If a workshop inspection is possible: Remove the intercooler outlet hose and check for oily deposits inside. Look here: Engine crankcase ventilation system, varies by engine side