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Volvo2002–2023 Critical issues documented

Volvo XC90 P2: common faults & what to check

The P2 is the Volvo XC90 built 2003–2015. It was sold here with the 2.4 diesel, 2.5 turbo petrol, 3.2 petrol, and 4.4 V8 petrol. Of the 27 faults documented for the XC90, 13 apply to this generation, each with its symptoms, what to inspect and a typical repair cost. Free, no account needed.

Check this exact Volvo XC90

  • Odometer history
  • Money owing
  • Reported stolen
  • Ownership history
  • Official NZ vehicle register data
  • NZ owned and operated

Type the plate for the free basics. The full record is a paid check from $13.49, one car at a time, no subscription.

No NZ plate yet, or buying in Australia? Pick the generation and engine and start a free check below. New to KickTyres? How the check works →

27

Documented faults

Critical

Most serious

$800–$2,500

Typical repair

24

Service milestones

You're looking at the P2

4 engine variants are documented for this generation. Pick yours to narrow further, or keep reading for the generation as a whole.

Choose a different generation

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

A 2003 Volvo XC90 is the P2 generation (2003 to 2015).

Start your free check on this Volvo XC90

No plate needed. You get the risk score, the buyer's checklist and the guided inspection for the exact car you picked above — not the whole nameplate.

Volvo XC90 P2Engine not picked yet

Pick the engine above first: the XC90 came with 4, and without it the report has to show all of their faults. Pick the engine

Free. The paid plate check is separate, and stays optional.

Can't confirm for this car

Volvo XC90 · 2003

Narrowed to the year. No engine is recorded for this vehicle. Pick an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

  • No engine is recorded for this vehicle.

matched on year only

What to look out for

The checks worth doing on a Volvo XC90 before you hand over any money. Every documented fault is listed below, each with its own page.

  • Serious issue

    Scan for stored P1693 or ETM-related codes before purchase.

    See why

    Electronic Throttle Module (ETM) Failure

    The ETM is a drive-by-wire throttle unit in which the internal potentiometer track suffers carbon erosion over time. Failure causes sudden engine stall at highway speed or a no-start condition after stall, creating a serious safety hazard. Volvo issued an extended warranty and replacement program globally, but many high-km NZ/AU imports have reverted to unrepaired or cheaply repaired units.

    What you would notice

    • Sudden engine stall at speed with no warning
    • Engine refuses to restart after stall
    • Erratic or unresponsive throttle pedal
    • Check engine light with P1693 or throttle position fault codes

    Typically $800–$1,800 to put right.

  • Worth checking

    With the engine running, turn the wheel lock to lock and listen for pump whine which indicates low fluid from a leak.

    See why

    Power Steering Hose and Rack Seepage

    The hydraulic power steering system on the XC90 C/D uses high-pressure hoses and a rack-mounted pump that are prone to slow seepage once the rubber hose fittings age past 10–12 years. The most common leak points are the high-pressure hose at the pump union and the rack end seals. Power steering fluid loss causes increasing steering heaviness, pump whining, and — if ignored long enough — complete loss of assisted steering.

    What you would notice

    • Whining or moaning noise from steering pump on turning
    • Increased steering effort, especially at low speed
    • Power steering fluid level dropping in reservoir
    • Visible reddish/brown fluid residue around steering rack or pump

    Typically $300–$1,400 to put right.

Volvo XC90 service schedule

The 2 engines a 2003 Volvo XC90 was sold with, each with its own intervals. Pick your engine above to narrow this to one. These are the model’s intervals — the car’s own service book is the only thing that can tell you what has actually been done to it.

First Generation (P2) · 2002–2006 · 2.9L (B6294T) - T6 Twin Turbo Petrol

Petrol

Due by distance

  1. 150,000 km

    Assess the cooling system hoses and how healthy the radiator still is.

  2. 200,000 km

    Suspension parts and mounts want checking here for rubber that has perished.

  3. 250,000 km

    A sensible time to inspect the turbo oil feed lines and make sure the vacuum lines are all sound.

First Generation (P2) · 2002–2014 · 2.5L (B5254T2) - 2.5T Turbo Petrol

Petrol

Due by distance

  1. 150,000 km

    Suspension bushings and control arms start showing their age here, especially on New Zealand's mixed road surfaces.

  2. 200,000 km

    Check where things stand with the turbocharger's oil feed lines and the health of the PCV breather system.

  3. 250,000 km

    Make sure every auxiliary belt and pulley has been renewed so the B5254T2 engine keeps running dependably.

See all 13 issues for this oneDocumented for the exact year and engine you picked, including 5 rated critical.
Electrical2 critical2

01ARC airbag inflator rupture risk — active safety recall

2003–2014Electrical
RareElectrical $0–$2,500 to fix

Volvo XC90 first-generation vehicles produced between 2003 and 2014 were fitted with ARC (Automotive Systems Laboratory / ARC Automotive) airbag inflators in driver, passenger, and in some cases side curtain positions. ARC inflators have been subject to NHTSA investigation and formal recall campaigns due to a manufacturing defect that can cause the inflator housing to rupture explosively upon deployment, propelling metal fragments into the occupant compartment. The failure mode is similar to the Takata recall and is equally severe. Unlike Takata, the ARC recall was still active and incomplete as of 2025, meaning many vehicles had not yet received the remedy.

Symptoms to notice

  • No symptoms prior to deployment — failure only manifests in a crash event
  • Recall notification letter from Volvo Cars if registered correctly

What to check

Use the VIN to check the NHTSA recall database at nhtsa.gov/recalls and the New Zealand NZTA recall database to confirm whether outstanding recalls apply to this specific vehicle. Verify with the seller or a Volvo dealer whether the recall remedy has been completed and request the dealer completion record.

Where to look: Airbag inflator modules behind the steering wheel hub, dashboard passenger side, and A/B pillar curtain positions

Ask the seller

  • “Has this vehicle been checked against the NHTSA or NZTA airbag recall database?”
  • “Has the airbag inflator recall been completed at a Volvo dealer?”
  • “Do you have the dealer completion paperwork for the recall?”

02Electronic Throttle Module (ETM) Failure

Scan for stored P1693 or ETM-related codes before purchase.petrol2002–2006Electrical
CommonElectrical $800–$1,800 to fix

The ETM is a drive-by-wire throttle unit in which the internal potentiometer track suffers carbon erosion over time. Failure causes sudden engine stall at highway speed or a no-start condition after stall, creating a serious safety hazard. Volvo issued an extended warranty and replacement program globally, but many high-km NZ/AU imports have reverted to unrepaired or cheaply repaired units.

Symptoms to notice

  • Sudden engine stall at speed with no warning
  • Engine refuses to restart after stall
  • Erratic or unresponsive throttle pedal
  • Check engine light with P1693 or throttle position fault codes

What to check

  1. Scan for stored P1693 or ETM-related codes before purchase.
  2. Ask for documentary evidence of ETM replacement under the Volvo extended warranty program.
  3. Start the engine from cold and perform several hard throttle stabs — any hesitation or stall is a red flag.
  4. Verify the unit fitted is a revised post-2003 part number via VIDA if possible.

Where to look: Throttle body on intake manifold, engine bay

Ask the seller

  • “Has the ETM been replaced under the Volvo extended warranty program?”
  • “Are there any service records showing the replacement part number?”
  • “Has the vehicle ever stalled suddenly while driving?”
Fluid leaks1

03Power Steering Hose and Rack Seepage

With the engine running, turn the wheel lock to lock and listen for pump whine which indicates low fluid from a leak.2002–2014Fluid Leaks
OccasionalFluid Leaks $300–$1,400 to fix

The hydraulic power steering system on the XC90 C/D uses high-pressure hoses and a rack-mounted pump that are prone to slow seepage once the rubber hose fittings age past 10–12 years. The most common leak points are the high-pressure hose at the pump union and the rack end seals. Power steering fluid loss causes increasing steering heaviness, pump whining, and — if ignored long enough — complete loss of assisted steering.

Symptoms to notice

  • Whining or moaning noise from steering pump on turning
  • Increased steering effort, especially at low speed
  • Power steering fluid level dropping in reservoir
  • Visible reddish/brown fluid residue around steering rack or pump

What to check

  1. With the engine running, turn the wheel lock to lock and listen for pump whine which indicates low fluid from a leak.
  2. Inspect the power steering reservoir level and note the fluid colour.
  3. Get under the vehicle and inspect the steering rack boots and the pump-to-rack high-pressure hose for wetness or dried fluid residue.

Where to look: Power steering pump (front of engine), high-pressure hose, and steering rack underneath the vehicle

Parts involved: Steering rack.

Ask the seller

  • “Has the power steering fluid level been dropping?”
  • “Have any power steering hoses been replaced?”
  • “Does the steering ever feel heavier than normal or make noise on turning?”
Depends on the exact engine — 10 moreDocumented for a specific engine we could not confirm from what you picked. Check the engine code on the car.
Engine, transmission & cooling9

01Timing Belt Failure — D5244T 2.4D Diesel

Request documentary proof of timing belt replacement showing date and odometer reading.diesel2003–2014Engine
CommonEngine $700–$9,000 to fix

Can't confirm for this car

The D5244T 2.4L five-cylinder diesel uses a rubber timing belt to drive the camshafts. Volvo specifies replacement at 130,000 km or 10 years. The engine is an interference design, so belt snap or tooth-skip causes immediate piston-to-valve contact and total engine destruction. Many NZ/AU used imports arrive with no timing belt history, and owners underestimate the consequence of an overdue belt.

Symptoms to notice

  • Engine will not crank or start after belt snap
  • Loud ticking or slapping from cam area if belt is slipping
  • Misfires and rough running as belt loses tension
  • Sudden catastrophic engine failure at highway speeds

What to check

  1. Request documentary proof of timing belt replacement showing date and odometer reading.
  2. If no proof exists, budget for immediate replacement before purchase.
  3. Ask if the water pump was replaced at the same time — it is driven off the same belt and failure floods the belt.
  4. Inspect the auxiliary belt condition as an indicator of overall service discipline.

Where to look: Front of engine behind plastic timing cover, driver's side

Parts involved: Timing belt.

Ask the seller

  • “When was the timing belt last replaced and at what odometer reading?”
  • “Was the water pump replaced at the same service?”
  • “Are there workshop receipts confirming the belt replacement?”

02T6 (2.9 twin-turbo) GM 4T65EV automatic transmission failure

Ask upfront if the transmission has ever been replaced or rebuilt and see the invoice - on a T6 this is the single most important question.petrol2003–2006TransmissionRead the full fault: symptoms, where to look, what to ask the seller

03Turbocharger Oil Starvation — B6294T 2.9TT

Inspect the intercooler pipes for oil contamination — any internal oiling indicates a failing turbo seal.petrol2002–2006Engine
OccasionalEngine $2,500–$6,000 to fix

Can't confirm for this car

The twin-turbocharged B6294T 2.9L engine relies on adequate oil flow to both turbocharger bearing housings. Degraded oil, extended service intervals, or an already-failing oil separator causes oil coking in the turbo oil feed lines, starving the bearings. Bearing seizure follows, sending metal fragments into the compressor and sometimes the engine. A turbo replacement with associated oil system flush is required.

Symptoms to notice

  • Loud whining or grinding from turbo area under load
  • Blue/black smoke under full throttle acceleration
  • Loss of boost pressure and significant power reduction
  • Oil on the intercooler or in the intake piping

What to check

Inspect the intercooler pipes for oil contamination — any internal oiling indicates a failing turbo seal. With the engine warm, snap the throttle and watch for blue smoke. Verify oil service records are complete and intervals have not been extended. If a workshop inspection is possible: Remove the intake hose from the compressor inlet and check the compressor wheel for play or oil fouling.

Where to look: Twin turbochargers mounted on exhaust manifold, front of engine

Parts involved: Turbocharger.

Ask the seller

  • “Have the turbochargers ever been rebuilt or replaced?”
  • “What oil brand and interval has been used throughout ownership?”
  • “Has the oil separator been replaced on this engine?”

04Haldex AWD Coupling Failure — Neglected Fluid Service

Find the Haldex unit under the rear of the vehicle and inspect for fluid leaks or burnt residue around the casing.2002–2014TransmissionRead the full fault: symptoms, where to look, what to ask the seller

05D5244 diesel EGR cooler matrix cracking and coolant loss

Check coolant reservoir for oil contamination (brown frothy emulsion).diesel2002–2014CoolingRead the full fault: symptoms, where to look, what to ask the seller

06PCV/crankcase breather system clogging causing oil leaks (2.5T and 3.2)

petrol2003–2014EngineRead the full fault: symptoms, where to look, what to ask the seller

07B6294T Rear Main Seal Oil Leak

Inspect the rear of the engine block at the transmission bellhousing junction with a torch and mirror.petrol2002–2014EngineRead the full fault: symptoms, where to look, what to ask the seller

08Throttle Body Carbon Buildup Causing Idle Hunt

Inspect the throttle body bore and plate for heavy carbon deposits.petrol2002–2010Engine
CommonEngine $150–$600 to fix

Can't confirm for this car

The electronic throttle body on B5254T2 and B6294T petrol engines accumulates carbon deposits on the throttle plate and bore, disrupting idle air control and causing rough or hunting idle. The throttle body requires periodic cleaning — typically at 100,000km intervals — but is often overlooked. In severe cases, the throttle body must be replaced as the bore develops pitting. Documented across multiple Volvo specialist workshops and online forums as a predictable service item.

Symptoms to notice

  • Rough or fluctuating idle, especially when cold
  • Idle surging between 500 and 1000 RPM
  • Hesitation on light throttle from standstill
  • Engine management or throttle position warning light

What to check

  1. Inspect the throttle body bore and plate for heavy carbon deposits.
  2. Start the car from cold and observe idle stability over 2–3 minutes.
  3. If a workshop inspection is possible: Scan for throttle position sensor adaptation faults with OBD diagnostics.

Where to look: Engine intake manifold, electronic throttle body assembly

Ask the seller

  • “Has the throttle body been cleaned or replaced?”
  • “Does the car idle smoothly when cold?”
  • “Are there any engine management lights or fault codes present?”

09AW55-50SN Automatic Gearbox Valve Body Fault

Check transmission fluid condition on the dipstick — burnt smell or dark colour indicates overdue servicing.2002–2014Transmission
OccasionalTransmission $1,200–$4,000 to fix

Can't confirm for this car

Early XC90 models fitted with the Aisin Warner AW55-50SN five-speed automatic transmission suffer from valve body solenoid wear and internal seal degradation. The solenoids control hydraulic pressure to each clutch pack; worn solenoids cause erratic gear changes, slipping between gears, or the transmission defaulting to third gear (limp home mode). Valve body replacement or overhaul is the typical repair. Fluid that has never been changed accelerates solenoid wear significantly.

Symptoms to notice

  • Harsh or jerky gear changes especially 1-2 and 2-3
  • Transmission slipping or flaring under acceleration
  • Stuck in third gear (limp mode) with transmission warning light
  • Delayed engagement when selecting Drive or Reverse

What to check

  1. Check transmission fluid condition on the dipstick — burnt smell or dark colour indicates overdue servicing.
  2. On a test drive, note shift quality at all throttle positions and listen for any slipping flare.
  3. Scan for transmission fault codes before purchase.
  4. Ask for automatic transmission fluid change history.
  5. Fluid neglect is the primary accelerant for this failure.

Where to look: Automatic transmission pan, valve body inside the gearbox casing

Parts involved: Mechatronic / valve body.

Ask the seller

  • “Has the automatic transmission fluid ever been changed?”
  • “Has the vehicle ever been in limp mode?”
  • “Are there any transmission fault codes stored?”
Fluid leaks1

01PTU power transfer unit bearing and output seal failure

Inspect the driver-side transaxle area for oil staining on the PTU case and surrounding subframe.2002–2014Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller
Other Volvo XC90 engines and years14 documented issues that do not apply to the one you picked.
Engine, transmission & cooling7

01EGR and DPF Failure — D4204T Diesel in XC90 L

Scan ECU for DPF soot loading percentage and EGR fault codes.diesel2014 onwardEngineRead the full fault: symptoms, where to look, what to ask the seller

02Spark Plug Seizure in Aluminium Head — B6324S

Ask when plugs were last changed and at what interval.petrol2007–2014Engine
OccasionalEngine $600–$3,500 to fix

Does not apply

The B6324S 3.2L aluminium cylinder head uses steel-shelled spark plugs. If plugs are left beyond recommended replacement intervals — or installed without anti-seize compound — the dissimilar metals bond under heat cycling. Attempts to remove seized plugs result in the plug body snapping off in the head, requiring helicoil thread repair or in severe cases cylinder head removal. The failure is especially common on higher-mileage NZ/AU vehicles where service records are incomplete.

Symptoms to notice

  • Misfires or rough running from plugs due for replacement
  • Plug thread damage discovered during routine service
  • Broken spark plug electrode fragment in cylinder (post-snap)
  • Engine damage codes from misfire caused by fractured plug

What to check

Ask when plugs were last changed and at what interval. Inspect service records for plug replacement at the recommended 60,000–80,000 km. If no history exists, budget for plug replacement immediately and use a workshop experienced with Volvo aluminium heads. Do not attempt plug removal without penetrating lubricant pre-soak on a cold engine.

Where to look: Top of cylinder head, six plug locations under coil-on-plug units

Parts involved: Cylinder head.

Ask the seller

  • “When were the spark plugs last replaced?”
  • “Were they removed by a Volvo-experienced workshop?”
  • “Is there any documented misfire history?”

03D5 swirl flap linkage failure and EGR/inlet manifold carbon build-up

Scan for codes before purchase - P2015 or history of it is the tell.diesel2005–2014EngineRead the full fault: symptoms, where to look, what to ask the seller

04Drive-E Coolant System Failure — Water Pump and Plastic Manifold

With the engine cold, visually inspect the plastic coolant manifold and all junction hoses for white calcium residue or cracking.petrol2014 onwardCooling
OccasionalCooling $800–$2,500 to fix

Does not apply

The Drive-E B4204T engine uses an electric auxiliary coolant pump and a plastic coolant distribution manifold that are both known failure points. The manifold develops hairline cracks with age and heat cycling, causing slow coolant loss. The auxiliary electric pump motor can also fail, reducing coolant circulation and causing the engine to run hot. Loss of coolant pressure on a turbocharged engine leads to rapid overheating, potential head gasket failure, and expensive repairs.

Symptoms to notice

  • Coolant low warning light with no obvious external leak
  • Temperature gauge rising above normal range
  • Sweet smell from engine bay after driving
  • Coolant residue or white staining around hose junctions or manifold

What to check

  1. With the engine cold, visually inspect the plastic coolant manifold and all junction hoses for white calcium residue or cracking.
  2. Check the coolant level against the reservoir — any drop since the last service is a warning sign.
  3. Start the engine and listen for the auxiliary pump operating (slight hum from the secondary coolant circuit).
  4. Scan for coolant temperature fault codes.

Where to look: Top of engine, plastic coolant distribution manifold near firewall

Parts involved: Water pump.

Ask the seller

  • “Has the coolant level been dropping between services?”
  • “Has the plastic coolant manifold been replaced?”
  • “Has the vehicle ever overheated or shown a temperature warning?”

05Drive-E T6 Supercharger Belt Tensioner Failure

Test drive the vehicle and pay attention to throttle response from 1000-2500 RPM — a healthy T6 should deliver immediate, strong torque from low revs.petrol2015 onwardEngine
OccasionalEngine $700–$1,800 to fix

Does not apply

The Drive-E T6 engine in the second-generation XC90 L pairs a low-pressure turbocharger with a belt-driven supercharger for wide power delivery. The supercharger drive belt tensioner is a known failure point, with the spring fatiguing or the idler bearing seizing and causing belt slip or complete separation. When the supercharger loses drive, low-to-mid range boost is eliminated and the car reverts to turbocharger-only performance, which is noticeably weaker below 2500 RPM. A failing tensioner bearing typically produces a squeal or chirp before belt separation, and a shed belt can cause secondary damage to nearby ancillary components.

Symptoms to notice

  • Marked loss of acceleration below approximately 2500 RPM; car feels underpowered at low speeds
  • Engine or boost performance warning light on the instrument cluster
  • Squealing or chirping from the front of the engine under light throttle or at startup
  • Car accelerates more weakly than expected for a T6 from a standing start
  • Belt debris in the engine bay in cases of complete belt failure

What to check

Test drive the vehicle and pay attention to throttle response from 1000-2500 RPM — a healthy T6 should deliver immediate, strong torque from low revs. If the car feels sluggish until higher RPM, supercharger drive may be compromised. Physically inspect the supercharger drive belt for cracking, glazing, or fraying. Listen for bearing squeal or chirp from the tensioner area. If a workshop inspection is possible: Scan for OBD boost or performance fault codes.

Where to look: Front of engine, supercharger belt and tensioner idler pulley assembly

Parts involved: Timing belt.

Ask the seller

  • “Has the supercharger belt or tensioner ever been replaced?”
  • “Has any boost or engine performance warning light appeared?”
  • “Has sluggish or reduced acceleration been noticed, especially at lower speeds?”
  • “Has any squealing been heard from the engine bay?”

06Oil Separator (PCV/Oil Trap) Blockage — B6324S 3.2L

Inspect the PCV hoses for cracks or oil weeping.petrol2006–2014EngineRead the full fault: symptoms, where to look, what to ask the seller

07Aisin TG-81SC 8-speed gearbox harsh shifting and calibration fault

Test drive the vehicle from cold, paying particular attention to the quality of upshifts during gentle acceleration from stop.petrol2014 onwardTransmission
CommonTransmission $250–$1,200 to fix

Does not apply

The second-generation XC90 and XC60 Drive-E models use the Aisin Warner TG-81SC 8-speed torque converter automatic gearbox. Early production calibration files cause the transmission control unit to apply clutch packs too aggressively during 1-2, 2-3, and 7-8 upshifts under light to moderate throttle, producing a noticeable jerk or thump. The condition is most pronounced when the transmission fluid is cold and the hydraulic control system oil is at high viscosity. Volvo released multiple TCU software updates addressing the shift quality map. Vehicles that have not received the latest calibration still exhibit the harsh shift behaviour, which can accelerate clutch pack wear over time.

Symptoms to notice

  • Jerky or thudding gear changes particularly during gentle acceleration
  • Harsh 1-2 upshift when the gearbox is cold
  • Hesitation followed by a firm shift at light throttle cruise speeds
  • Sensation of the car surging then settling during upshifts

What to check

  1. Test drive the vehicle from cold, paying particular attention to the quality of upshifts during gentle acceleration from stop.
  2. Check the transmission fluid service history — contaminated or degraded fluid worsens the shift quality.
  3. If a workshop inspection is possible: Verify with a Volvo dealer or VIDA diagnostic tool whether the latest transmission calibration software has been applied to the TCU.

Where to look: Transmission control unit and valve body within the 8-speed automatic gearbox, beneath the vehicle

Parts involved: Torque converter, Clutch.

Ask the seller

  • “Has the Volvo dealer applied the latest transmission software update?”
  • “Has the gearbox ever been investigated for harsh or jerky shifting?”
  • “When was the transmission fluid last changed?”
Electrical2

01T8 PHEV 12V Auxiliary Battery Drain & Gremlins

hybrid2015 onwardElectricalRead the full fault: symptoms, where to look, what to ask the seller

02Sensus infotainment lag, freezes and centre-screen blackouts

Time the screen from ignition-on to fully responsive, then stress it: navigation, media, phone pairing and reversing camera in one session.2015–2021Electrical
CommonElectrical $150–$2,500 to fix

Does not apply

2015-2021 XC90s run the Sensus portrait touchscreen, which controls nearly everything including climate - and on early software it was laggy, prone to freezing, and 2016 cars in particular could black out entirely while driving. Multiple software updates improved stability, so the difference between an updated and un-updated car is night and day. Out of warranty, a failed centre display or infotainment module is an expensive part. From 2022 the facelift moved to the Google-based system.

Symptoms to notice

  • Very slow boot after start-up
  • Touch inputs lagging or being missed
  • Screen freezing, rebooting or going black mid-drive
  • Climate controls unavailable during screen crashes

What to check

Time the screen from ignition-on to fully responsive, then stress it: navigation, media, phone pairing and reversing camera in one session. Any reboot during the viewing is a bad sign. Ask a dealer to confirm the latest software level for the VIN and whether the centre display has ever been replaced.

Where to look: Portrait centre touchscreen and infotainment module in the dash

Ask the seller

  • “Is the Sensus software on the latest release?”
  • “Has the screen ever frozen or gone black while driving?”
  • “Has the display or infotainment module been replaced?”
Body, brakes, suspension & interior4

01T8 plug-in: regenerative-braking software recall ('B' mode brake loss risk)

hybrid2020 onwardBrakes
RareBrakes $0–$800 to fix

Does not apply

Volvo's mid-2025 global software recall (over 400,000 vehicles) covered plug-in hybrids including recent XC90 T8s: continuous regenerative braking while coasting downhill in 'B' mode could momentarily cause a loss of hydraulic brake function. The remedy is a free brake-control software update, over-the-air or at a dealer, and Volvo advised owners not to use 'B' mode until it was applied. Any T8 buyer should confirm by VIN that the recall is done and the car is on current software; friction discs on hybrids can also rust from light use since regen does most everyday braking.

Symptoms to notice

  • Recall outstanding on the VIN
  • Inconsistent pedal feel as regen blends into friction braking
  • Rust-scored brake discs from under-use
  • Brake system warning messages

What to check

Have a Volvo dealer (or the manufacturer recall lookup) confirm the 2025 brake software recall is completed for this VIN, and check the software version in the settings menu. On the test drive use 'B' mode on a downhill and also perform a firm stop from 80 km/h to confirm strong, consistent friction braking. Look through the wheels for heavily rusted or lipped discs.

Where to look: Brake control module (software); discs behind each wheel

Ask the seller

  • “Has the 2025 brake software recall been completed on this VIN?”
  • “Is the software up to date (OTA or dealer)?”
  • “When were discs and pads last replaced?”

02Second row seat belt buckle anchor screw recall REC-005861 (second generation XC90, 2015-2023)

Ask for proof the seat belt recall (REC-005861) was done, or have a Volvo dealer check the VIN.2015–2023Interior
OccasionalInterior $0–$400 to fix

Does not apply

On the second generation Volvo XC90 (all engines including the T8 plug-in, 2015-2023) the screw holding a second row seat belt buckle and lower anchor may work loose, so the belt may not restrain a passenger properly in a crash. Volvo Australia recalled these cars under REC-005861 and the fix is free at a Volvo dealer. Not every car in these years is in the recall; a dealer check of the VIN is the only way to know.

Symptoms to notice

  • Second row seat belt buckle moves or wobbles at its base

What to check

Ask for proof the seat belt recall (REC-005861) was done, or have a Volvo dealer check the VIN. In the second row, grab each belt buckle and lower belt anchor and pull and twist: there should be no movement at the base. If a workshop inspection is possible: the dealer can check the anchor screw torque.

Where to look: Second row seat belt buckles and lower anchors

Ask the seller

  • “Has the second row seat belt recall been done for this VIN?”

03Air suspension compressor failure (blown 40A fuse) - Volvo QB-100 extended warranty

See the car after it has sat overnight and confirm it is level and at normal height.2016–2020SuspensionRead the full fault: symptoms, where to look, what to ask the seller

04Air Suspension Compressor Membrane Failure

With the engine running, observe whether the car raises to normal ride height within approximately 30-60 seconds.2015 onwardSuspension
OccasionalSuspension $1,400–$3,200 to fix

Does not apply

The optional Four-C air suspension on the second-generation XC90 L uses an electric compressor with a rubber diaphragm membrane to pressurize the air springs at each corner. The membrane fatigues and cracks over time, particularly with temperature cycling, preventing the compressor from building adequate pressure. When the membrane fails the suspension drops to its lowest position, a Suspension Service Required or height fault warning appears, and the vehicle rides extremely harshly on the bump stops. The compressor may run continuously and audibly as it attempts in vain to build pressure.

Symptoms to notice

  • Vehicle sitting noticeably lower than normal ride height on one or more corners
  • Suspension Service Required or Air Suspension height fault warning on the driver display
  • Very harsh, jarring ride quality with no effective damping
  • Electric air compressor audible running continuously for more than 30 seconds after startup
  • Car slow to rise to normal ride height or failing to achieve target height
  • Air suspension fault codes present on diagnostic scan

What to check

  1. With the engine running, observe whether the car raises to normal ride height within approximately 30-60 seconds.
  2. Toggle between driving modes (Comfort, Dynamic) and check that the suspension responds correctly.
  3. Listen for the compressor running continuously without the car rising — this indicates failure to build pressure.
  4. Ask the seller to demonstrate all height mode selections including the raised off-road position.
  5. Request a diagnostic scan for air suspension fault codes.
  6. Ask about any height warning history.

Where to look: Air suspension compressor pump under the rear cargo floor or rear wheel arch; air springs at all four wheel corners

Parts involved: Air suspension strut.

Ask the seller

  • “Has the car ever displayed a suspension warning or height system fault?”
  • “Does the car sit at the same height on all four corners when viewed from the outside?”
  • “Has the air suspension compressor ever been replaced or repaired?”
  • “Has the car ever been recovered or been unable to drive due to suspension dropping?”
Fluid leaks1

01B4204 2.0 engine crankshaft seal oil leak from clogged PCV system

Torch the underside of the engine, particularly around the crank pulley and the bellhousing join, for fresh oil.2015 onwardFluid Leaks
OccasionalFluid Leaks $900–$2,800 to fix

Does not apply

Every second-generation XC90 uses the 2.0-litre four (petrol T5/T6, diesel D5, and the T8's petrol engine), and its PCV breather clogs with age, building crankcase pressure that pushes oil past the front or rear crankshaft seal - commonly seen from around 100,000-150,000 km. Replacing only the seal without addressing the PCV system means the leak returns, and the front seal requires timing-drive work so labour dominates the bill. Well documented on SPA-platform Volvos across owner forums.

Symptoms to notice

  • Oil drips or misting under the engine
  • Oil at the engine-to-gearbox join
  • Burning oil smell after motorway running
  • Oil level dropping between services

What to check

Torch the underside of the engine, particularly around the crank pulley and the bellhousing join, for fresh oil. Check the driveway or parking spot for drips. At idle, feel for excess pressure at the oil filler. Ask whether any leak repair included PCV cleaning/replacement - insist on seeing the invoice wording.

Where to look: Crankshaft seals at both ends of the engine, low down; PCV system integrated into the engine

Parts involved: PCV / oil separator.

Ask the seller

  • “Any oil leaks repaired, and was the PCV system serviced with them?”
  • “Does it mark its parking spot?”
  • “How much oil does it use between services?”

Volvo XC90 faults in detail

Narrowed to the Volvo XC90 · 2003. Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

B6294T Rear Main Seal Oil LeakMajor · EngineD5244 diesel EGR cooler matrix cracking and coolant lossMajor · CoolingHaldex AWD Coupling Failure — Neglected Fluid ServiceMajor · TransmissionPCV/crankcase breather system clogging causing oil leaks (2.5T and 3.2)Major · EnginePTU power transfer unit bearing and output seal failureMajor · Fluid LeaksT6 (2.9 twin-turbo) GM 4T65EV automatic transmission failureCritical · Transmission

What these repairs cost on other cars

Some of the Volvo XC90’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Volvo models

Volvo XC6020 documented faultsVolvo S6018 documented faultsVolvo XC4016 documented faultsVolvo V6011 documented faultsVolvo XC706 documented faults

Volvo XC90 buyer questions

Is the Volvo XC90 reliable?

Like any used car, it depends on the specific example and its service history. Across the 27 documented faults for the Volvo XC90, the recurring problem areas are engine, transmission, and electrical. A Volvo XC90 with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.

What are the most common problems with a used Volvo XC90?

We've catalogued 27 known faults for the Volvo XC90, covering engine, transmission, and electrical. All 27 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Volvo XC90?

Most single repairs on the Volvo XC90 fall between $800–$2,500 at NZ independent-workshop rates. Some of the 27 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.

Should I get a pre-purchase inspection on a Volvo XC90?

Yes. A Volvo XC90 inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $24.90 far less than the cost of missing one of the faults on this page.