Volvo S90 D5 AWD Reliability

The D5 PowerPulse uses a twin-turbo setup (one fixed geometry, one variable geometry) in series. Symptoms of failure include steady power loss, heavy exhaust smoke (blue or black), high-pitched whine from the engine bay, increased oil consumption as seals wear, and inconsistent boost response. Multiple owners report finding significant oil in the intake pipes and loose turbo shaft play. The complexity of the twin-turbo system with PowerPulse means replacement requires extensive calibration. One documented dealer quote for a 2020 S90 D5 was €14,000 for turbo replacement and calibration. Turbo failures typically occur between 80,000-150,000 km, especially on cars driven gently or mostly short trips which don't allow the turbos to reach operating temperature regularly.

This is a known and very common issue on 2017-2018 S90 D5 models. The PowerPulse system stores compressed air in a tank and injects it into the exhaust manifold to spin up the turbo instantly. The high-pressure hose connecting the tank to the exhaust manifold has connector clamps that can fail, causing the hose to burst or detach. Some owners report a "massive explosion" sound when parked, followed by noticeable loss of low-rev power and torque. Volvo acknowledges this issue and released an updated part. Multiple owners report hose failures at 50,000-80,000 km. Check for hissing sounds after engine shutdown or listen for the PowerPulse compressor at startup (near the front right wheel arch). Some owners on forums report being on their third replacement hose. Repair cost at dealer is approximately €500 (parts + labor), though Volvo sometimes offers goodwill contributions on XC90s but inconsistently on S90s.

The EGR valve on the D5 engine tends to clog with carbon and soot over time, especially on cars used for short trips. Symptoms include check engine light, engine cutting out randomly, reduced power, rough idle when stopped, stronger than usual exhaust smell, and limp mode. The EGR valve fills the intake with carbon and grease mixture, gradually restricting airflow. Both EGR and PowerPulse hose issues are quite common on the D5. One owner reported paying €355 for a complete EGR valve replacement which resolved all symptoms. EGR cooler failures have also been reported causing excessive soot production and DPF clogging. The EGR pipe itself (metal pipe connecting EGR to manifold) can crack and require replacement at approximately €200-300. Regular motorway driving helps keep the EGR system cleaner. Failure typically occurs between 60,000-120,000 km depending on driving patterns.

The S90 offers optional air suspension (Four-C Active Chassis). When equipped, air suspension failures are expensive. The air bags/springs develop leaks as the rubber ages, typically showing as one corner sitting lower than others, suspension warning lights, or the car dropping overnight. Volvo S90 air bag suspension repair costs start from €2,200 per strut according to YourMechanic. A single air spring replacement costs €2,000-2,150 on average. The rear air springs have dust covers originally installed with substandard plastic zip ties that slip off - a known design flaw documented by Volvo technical journals. Once one air spring fails, the others typically follow within 12-24 months as they age similarly. Air suspension issues typically appear after 5-7 years or 80,000-120,000 km. Not all S90s have air suspension - many have conventional coil spring suspension which is far more reliable and cheaper to maintain.

The DPF (Diesel Particulate Filter) requires regular regeneration cycles where exhaust temperatures reach 600°C to burn off accumulated soot. If the car is mainly used for short trips (under 20 minutes), the DPF cannot complete regeneration cycles, leading to blockage. Symptoms include reduced power, black smoke, limp mode, increased fuel consumption, and DPF warning light. A faulty EGR system increases soot production, overloading the DPF faster. DPF cleaning costs €500-800, but if too damaged, replacement is €1,200-2,500. According to owner reports, the DPF needs 30-40 minutes of driving at 80+ km/h (50+ mph) on highways weekly to regenerate properly. Using low-quality diesel accelerates DPF clogging. If turbo seals fail, oil contamination can permanently damage the DPF requiring replacement. DPF issues typically appear between 80,000-150,000 km on cars with inappropriate driving patterns.

The S90 D5 uses an AdBlue (DEF) system to reduce NOx emissions. Common issues include: faulty AdBlue tank (€1,600-1,800 for replacement), AdBlue pump blockages, NOx sensor failures, SCR catalyst efficiency problems, false low AdBlue warnings even after filling, and freezing in cold climates. If the AdBlue tank runs completely dry, the engine will not restart after being switched off - Volvo explicitly warns never to run the tank empty. One 2018 S90 owner reported a faulty AdBlue tank replacement costing €1,620. Common error codes include P204F93 (AdBlue dosing error) and P20EE00 (NOx catalyst efficiency below threshold). Contamination from dirt getting in during refilling can damage the entire system, requiring complete flush. When SCR system fails, the engine enters low-performance mode with limited speed. Ensure the filler cap area is thoroughly cleaned before adding AdBlue to prevent contamination. AdBlue system issues typically appear between 60,000-120,000 km.

D5 diesel injectors can fail after 3-5 years, typically developing as cold start issues progressing to complete failure to start. Symptoms include engine misfires, check engine light, rough idle, vibrations, hesitation under throttle, reduced power, and eventually failure to start. Volvo's remedy typically involves replacing all injectors rather than just the faulty one to ensure consistent spray patterns. Dealer cost for all 4 injectors including labor is approximately €1,500-2,200. Independent specialists may charge €1,300-1,800. A single injector replacement costs approximately €350-400. Injectors tend to fail after 80,000-150,000 km. Using high-quality diesel fuel with detergent additives helps prevent premature failure. Low-quality fuel with contaminants accelerates injector clogging. This is not a DIY repair due to fire risk and complexity of the high-pressure fuel system.

The electronic parking brake (EPB) system has a recurring issue with corroded or broken wires in the wiring harness running to the brake actuators. Symptoms include "parking brake service needed" warnings, parking brake refusing to engage or disengage, one side (usually left) trying unsuccessfully to deploy, "parking brake not fully retracted" message, and continuous warning chimes while driving. The wiring corrodes inside the protective jacket, typically the brown or purple wire. One owner reported a €1,800 repair cost for wiring harness replacement. DIY repair involves identifying the broken wire with a multimeter and re-splicing with shrink wrap. Cold weather can trigger or worsen symptoms. The actuator motor itself can also fail from moisture causing internal cog rust, producing grinding/screeching sounds. Volvo requires rear brake pad replacement be done by authorized workshops due to EPB system integration. This issue typically appears on cars 4-6 years old or 80,000-120,000 km regardless of mileage. Avoiding "auto hold" in extremely cold weather may reduce failures.

The Sensus infotainment system is prone to software glitches causing screen freezing, unresponsive touchscreen, loss of sound from radio/navigation/parking sensors/turn indicators, volume control not working despite on-screen response, and random rebooting. Most issues are software-related rather than hardware failures. Basic fix: lock car and let it enter sleep mode (30 minutes), then restart. Soft reset: press and hold Home button for 20-30 seconds until screen restarts. If persistent, a factory reset may be needed (all settings lost, phones need reconnecting). Hard reset: disconnect battery for 15 minutes. Volvo releases regular software updates that fix bugs - ask dealer to install latest version during service. Some users report issues resolved by software upgrades. The system affects 2017-2021 S90 models. Most repairs are covered under warranty if car is young enough. Hardware screen replacement (rare) costs approximately €300-500. This is primarily an annoyance rather than a safety issue, though loss of parking sensors and turn indicator sounds can be concerning.

The 8-speed Aisin automatic transmission used in S90 D5 models is generally reliable, but some owners report rough shifting, delayed engagement when reversing or accelerating, "Transmission Acceleration Performance Reduced" warning message, transmission jumping into reverse with dash warning, jerky and slipping gear shifts, and slow response times. Issues often stem from transmission control module faults, faulty speed sensors, throttle position sensor problems, low transmission fluid, worn clutch packs, or solenoid malfunctions. One 2021 S90 hybrid owner with 140,000 km reported transmission control unit replacement costing approximately €1,000. Software updates can resolve many issues - check with dealer for available updates. Rough reverse engagement is particularly common. Transmission fluid changes at recommended intervals (typically 60,000-80,000 km) help prevent issues. Avoiding aggressive driving reduces stress on transmission components. Most problems appear between 80,000-150,000 km or on cars 5+ years old.

The D5 diesel engine uses a timing belt (not a chain). Volvo's official replacement interval for VED (D4/D5) engines was updated from 10 years/144,000 km to 10 years/90,000 km, whichever comes first. This is scheduled maintenance, not a random failure, but it's a significant cost to budget for. When replacing the timing belt, mechanics typically also replace the tensioner, idler pulley, water pump, and thermostat since they're deep in the engine. Total cost at Volvo dealer is approximately €1,400-1,600. Independent specialists charge €1,000-1,300. If the timing belt breaks while driving, catastrophic engine damage will occur as valves and pistons collide - this is an interference engine. Therefore, this maintenance must not be skipped. For a 5-year-old car driven at maximum annual mileage (18,000 km/year), the belt service is due at the fifth service. Always check when the belt was last changed when buying a used S90 D5.

VEA engines (D5, D4, D3, D2) produced until 2017 had a design flaw in the oil control piston rings. The original rings had very small drainage holes that easily blocked, causing engine oil to remain in the combustion chamber and burn with fuel, increasing oil consumption. Volvo redesigned the rings with much larger holes, but the new rings cannot be retrofitted to old pistons - both pistons and rings must be replaced. The new design was introduced in 2015, and S90 models (launched 2016 on SPA platform) should have the new design from factory. However, early 2016-2017 S90s with certain engine serial numbers may have the old design. Symptoms include consuming approximately 1L of oil every 4,000-5,000 km, dashboard warnings to add oil, blue smoke from exhaust on acceleration. Piston and ring replacement costs €2,000-4,000 depending on labor rates. This issue mainly affects 50,000-100,000 km cars. Most 2018+ S90 D5 models should not have this problem. Check service history for oil consumption complaints.

The S90 has over 20 electronic modules, and any can cause battery drain when the car is parked. Common culprits include satellite receiver module (drawing power when engine off - Volvo issued TSB with software update), Central Electronic Module (CEM) defect (causes multiple electrical issues), instrument cluster shorting internally, and various modules failing to enter low-power sleep mode. Normal parasitic drain for Volvos is 10-50 milliamps; some owners measure 300+ milliamps indicating a problem. Symptoms include battery dying after 5-10 days of not driving, low battery warnings, difficulty starting. Solution may be as simple as a software update (free if TSB applies) or may require module replacement (€300-400). The Battery Monitoring System (BMS) sensor mounted on negative terminal may need resetting: disconnect for 15 seconds with engine running, then reconnect. Volvo recommends replacing the battery every 4-5 years. Keeping car on a trickle charger when not in use for extended periods prevents drain issues. Check for open recalls or TSBs which may be repaired free of charge.