2015-2020 · 2.0L D5 twin-turbo diesel (225-235 hp) with PowerPulse
A premium 7-seater SUV known for safety and Scandinavian design. The D5 diesel offers strong torque and reasonable fuel economy (7-9 L/100km real-world). However, the 2016 model year is notorious for first-generation issues and should be avoided. Key concerns: air suspension failures on equipped models, sunroof drain blockages causing water damage, PowerPulse hose failures, AdBlue system faults, and the Aisin automatic gearbox requiring fluid changes despite being "sealed for life." The timing belt needs replacement at 90,000-108,000 km. Models from 2018 onwards show significantly improved reliability.
Air suspension compressor/strut failure€1,500 - €4,000
Air springs leak or compressor fails, typically after 4-5 years · more· less
Only applies to cars equipped with optional air suspension. The rear air springs have a known design flaw where factory-installed plastic zip ties slip off the dust covers, exposing the air springs to the elements. Each air spring costs €1,300-1,500 to replace. The compressor typically fails around the 4-5 year mark at approximately €600-700. Full system replacement can reach €10,000+. Consider conversion to conventional coil springs (€2,000-3,000) as a permanent solution. Volvo has issued a TSB acknowledging the dust cover issue.
Sunroof drain blockage / water damage€400 - €5,000
Clogged drains cause water to enter cabin, damaging electrics · more· less
A well-documented XC90 issue. The sunroof drain tubes become blocked, causing water to overflow into the cabin. In mild cases, you get wet carpets (€400-800 to clean/dry). In severe cases, water damages the wiring harness under the carpet, triggering electrical faults including the On Call system. One owner reported €5,000+ in damage and 33 days in the shop. The CEM (Central Electronic Module) can also be damaged if water enters through the plenum drain. Regular drain cleaning during service is essential prevention.
PowerPulse hose failure€300 - €600
High-pressure air hose bursts, disabling turbo lag elimination system · more· less
The PowerPulse system uses compressed air to eliminate turbo lag. The high-pressure hose connecting the air tank to the exhaust manifold is known to burst. When this happens, the ECU disables the compressor with no warning to the driver. You'll notice reduced low-end power and hesitation from standstill. Many owners had this replaced under warranty. An updated part is now used. The repair itself is relatively inexpensive but diagnosis can take time if the mechanic is unfamiliar with the system.
Diesel injector failure€1,500 - €2,800
Injectors fail causing misfires, hard starting, or fuel smell · more· less
The D5's diesel injectors can fail, particularly if poor-quality fuel has been used. Symptoms include reluctance to start (especially from cold), misfires, power loss, and in some cases fuel smell in the cabin from a leaking injector. A single injector replacement costs approximately €400-500 including labor, but dealers often recommend replacing all four (€2,500-2,800). Always test cold and hot starting before purchase - hesitation in either state suggests injector issues.
AdBlue/SCR system faults€500 - €2,000
NOx sensors, AdBlue pump, or level sensor failures trigger warnings · more· less
The AdBlue system required for Euro 6 emissions can cause various problems. NOx sensor failures trigger warning lights and can put the car in limp mode. The AdBlue pump can become blocked, and level sensors sometimes give false readings (showing empty when 75% full). Using cheap or contaminated AdBlue fluid exacerbates problems. If the tank is allowed to run completely empty, the car will not restart. NOx sensor replacement costs €500-800; full SCR system repairs can reach €2,000.
Automatic gearbox valve body wear€1,000 - €3,500
Aisin gearbox develops jerky shifts if fluid not changed · more· less
The 8-speed Aisin automatic gearbox is generally reliable but Volvo claims it's "sealed for life" - which is misleading. The fluid does degrade, especially with city driving and frequent shifting. Symptoms include hesitation, jerky shifts, and occasional slipping. Valve body replacement costs €1,000-1,500. Full gearbox rebuild runs €2,500-3,500. Prevention: change the gearbox fluid every 60,000 km using JWS3309-approved oil. This simple maintenance can prevent expensive repairs.
DPF clogging (short trip driving)€250 - €1,500
Diesel particulate filter clogs if regeneration cycles are interrupted · more· less
The DPF normally regenerates automatically during motorway driving. If the car is only used for short trips, the regeneration cycle never completes and soot builds up. Warning lights appear and the car may enter limp mode. Forced regeneration at a dealer costs €80-150. Professional cleaning costs €200-350. If severely clogged, DPF replacement runs €1,000-1,500. The DPF typically lasts 150,000-200,000 km with proper use. Not suitable for city-only driving.
Timing belt replacement€800 - €1,200
Scheduled replacement at 90,000-108,000 km - not a defect, but costly · more· less
The D5 engine uses a timing belt (not chain) that must be replaced at 90,000-108,000 km or 10 years, whichever comes first. This is scheduled maintenance, not a defect, but represents a significant cost. Always replace the water pump, tensioners, and pulleys at the same time. Failure to replace on schedule risks catastrophic engine damage if the belt snaps. Verify timing belt service history before purchase - this is non-negotiable.
Sensus infotainment freezing/lag€0 - €500
Touchscreen freezes, slow response, requires reset · more· less
Early XC90 II models (2015-2017) have slower Sensus hardware that can freeze or become unresponsive. This affects radio, navigation, climate controls, and parking sensors. Usually resolved by a soft reset (hold home button 20-30 seconds) or allowing the car to sleep for 30 minutes. Software updates have improved stability. In rare cases, the center display module needs replacement (€400-500). 2018+ models have upgraded hardware with better performance.
Wheel bearing failure€400 - €700
Growling noise from wheels, particularly at highway speeds · more· less
The XC90 has a known design characteristic that allows elements to reach the sealed wheel bearing races, causing premature wear. Symptoms include a growling or humming noise that increases with speed. Replacement cost is approximately €400-700 per wheel at an independent garage (dealers quote €600+ per wheel). The job takes about an hour per wheel if the hub isn't seized. Listen carefully during the test drive.
Control arm bushing wear€500 - €1,500
Front suspension bushings wear out around 80,000-100,000 km · more· less
The front lower control arm bushings typically wear out as the car approaches 80,000-100,000 km, especially with aggressive driving or rough roads. Symptoms include squeaking over bumps and wandering steering. Full control arm replacement costs €1,300-1,600, but having just the bushings pressed in costs €400-500 at an independent shop. Always replace in pairs (both sides).
Complex luxury SUV with above-average maintenance needs
The XC90 II D5 is a capable and comfortable 7-seater but carries typical European luxury SUV ownership costs. Avoid 2016 models which had numerous first-year issues. Cars from 2018+ are significantly more reliable. Key to long-term ownership: maintain the timing belt schedule, change gearbox fluid despite Volvo's "sealed for life" claim, keep sunroof drains clear, and ensure regular motorway driving for DPF health.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Volvo dealer or authorized specialist records essential. Verify timing belt replacement if over 90,000 km.
Tires
Check tread depth, age, and uneven wear patterns. XC90 is heavy and wears tires faster than average.
Cold start
Must start engine completely cold. Listen for unusual sounds and watch for smoke color.
Body condition
Check for rust, accident damage, paint mismatch. Inspect wheel arches and sills.
Test drive
Minimum 30 minutes including motorway speeds to allow DPF regeneration and gearbox warming.
Specific for this vehicle
Cold and hot start test
Test both cold start and restart when hot. Any hesitation suggests injector issues. Check for fuel smell in cabin.
Check air suspension operation (if equipped)
Raise and lower suspension using controls. Listen for compressor running excessively. Check for sagging overnight.
Inspect under carpets for water damage
Lift carpet edges in footwells and boot. Feel for dampness or musty smell indicating sunroof drain blockage.
Test Sensus infotainment system
Use all functions - navigation, climate, audio. Check responsiveness. Note any freezing or lag.
Listen for gearbox issues
During 30+ minute drive, feel for jerky shifts, hesitation, or clunking. Note gear changes at low speeds.
Check PowerPulse operation
From standstill, accelerate firmly. You should feel strong low-end torque. Hesitation suggests PowerPulse hose failure.
Verify timing belt service
Check service records for timing belt replacement. If over 90,000 km without documented replacement, walk away or budget €1,000+.
Listen for wheel bearing noise
At motorway speeds, listen for growling or humming that changes with speed. Test on smooth road surface.
Check AdBlue level and warnings
Verify AdBlue tank level matches display reading. Ask about any previous AdBlue-related warnings or repairs.
Recalls and Technical Service Bulletins
Coolant bleeder hose fire risk (2016 models)Verify completed
Contact Volvo with VIN to verify all recalls completed. The 2016 model year has the most recalls - extra scrutiny required for this year.
Warranty Status
Factory warranty3 years / 100,000 km (expired on most)
Corrosion warranty12 years from first registration
Extended warranty availableThrough Volvo dealers
Most 2015-2020 XC90s are outside factory warranty. Extended warranties are available through Volvo dealers. The 12-year corrosion warranty may still apply for rust-through on body panels. Warranty is transferable to subsequent owners.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.