Volvo S90 T5 SPA

A US class-action lawsuit alleged that 2013-2016 Volvo Drive-E engines (including the 2.0L four-cylinder used in early S90 T5s) had a piston ring defect that prevented proper oil scraping. The case was voluntarily dismissed in May 2023 after a private settlement. Volvo updated the piston and ring design midway through the 2016 model year, so later 2016 and 2017+ engines have improved internals. Affected cars consume 1 quart per 1,000-3,000 km. Topping up oil costs little, but a documented severe case may require piston/ring replacement at €4,000-8,000. Check the dipstick at every fill-up during ownership.

Brake disc warping is one of the most-reported S90 issues across What Car?, SwedeSpeed and Volvo Forums. Symptoms include pulsation through the brake pedal and a shimmy in the steering wheel above 100 km/h when braking. The cause is a combination of disc material and the heavy curb weight of the SPA platform. Many owners have had all four discs replaced under warranty within the first 50,000 km. Out of warranty, front disc and pad replacement runs €400-600; all four corners can reach €1,000-1,200. The problem often returns within 30,000-50,000 km of replacement.

The Sensus infotainment system is widely reported to freeze, reboot unexpectedly, or lose audio, navigation, climate display, and reversing camera function. Volvo has acknowledged ongoing problems and pushed multiple software updates without fully resolving them. A 30-minute sleep-mode reset (lock car, walk away) often clears the issue temporarily. If the unit itself fails, replacement at a dealer runs €1,500-2,500. Test every function (Apple CarPlay/Android Auto pairing, radio, climate display, reversing camera) on the test drive.

The plastic PCV oil separator becomes restricted by oil sludge and brittle tubing over time. Symptoms include oil mist around the engine, rough idle, whistling sounds, oil pushed past seals, and in severe cases blue smoke. Volvo specialists report clogged PCV systems on T5 engines as early as 80,000 km. Parts cost €100-200; labour is 4-6 hours because the intake manifold must come off. Independent specialists charge €400-700, dealers €700-900.

Volvo faced a class-action lawsuit over panoramic sunroof leaks across the SPA range. The four drain tubes can clog with leaves and debris, causing water to back up and enter the cabin from behind the rear-view mirror or down the A-pillar. Symptoms: damp headliner, wet front carpet, mouldy smell. Clearing the drains is a simple DIY job (€0-50). If water has already damaged the headliner, carpet, or electronic modules (yaw-rate sensor, audio amplifier), repair costs can reach €1,500-2,000. Always lift the carpet and check the footwell before purchase.

The S90 uses a main AGM battery plus a small auxiliary battery to support start-stop and various modules. The auxiliary battery is a common early failure (often by year 4-5), and an unresolved parasitic drain from one of 20+ control modules can flatten the main battery in days. Symptoms: ‘12V battery critical' warning, start-stop disabled, intermittent module faults. Auxiliary battery is €80-150 plus 30 minutes labour. Main AGM battery is €200-300 fitted. Module-related drain diagnosis at a dealer can add €200-400 in labour.

Forum reports document intermittent failures of the windscreen-mounted camera and front bumper radar, disabling Pilot Assist, City Safety, and adaptive cruise. Sometimes triggered by stone chips or windscreen replacement without proper recalibration. Recalibration costs €150-300; full camera or radar replacement €1,200-2,500. Always confirm the assist systems work on the test drive — try a short stretch of motorway with Pilot Assist engaged.