The Volvo S90 arrived in Australia in 2016 as a flagship large luxury sedan on the Scalable Product Architecture (SPA) platform, replacing the long-running S80. It is sold exclusively with 2.0-litre Drive-E four-cylinder engines — T5 (petrol), T6 (twin-charged petrol), D4 and D5 diesel, and the T8 Twin Engine plug-in hybrid — and shares underpinnings with the XC90 and V90, so documented issues on those siblings apply here too. Low local volumes make the S90 a distinctive used proposition, but also push repair costs above mainstream alternatives. Reliability is mixed: build quality is genuinely good, but recurring faults on the SPA platform mean a careful inspection is essential.
Sensus infotainment freezing and reboots
The portrait touchscreen running Volvo's Sensus Connect system is one of the S90's defining features — and one of its most common frustrations. Owners on forums and ProductReview-style sites regularly report the centre display freezing mid-drive, losing audio output, or entering a boot loop that repeatedly shows the Volvo logo without fully loading. When the display is stuck, the audio system, parking sensors and climate controls all stop responding.
- Affected: All S90 variants (2016–2023); most reported on 2017–2020 cars.
- Cause: Software memory management issues in the head unit; the system can also fail to wake from sleep mode.
- Fix: A hard reset (hold the Home button 20–30 seconds) clears many temporary freezes. Persistent issues need a dealer software update or, in severe cases, a head unit replacement. Volvo Australia's support pages acknowledge the issue and provide troubleshooting steps.
- Rough cost: Software update under warranty — free. Out-of-warranty unit replacement $1,500–$3,500 fitted.
On any test drive, cold-start the car and confirm the display loads fully, Bluetooth connects and navigation responds.
Drive-E engine oil consumption
The B4204-series 2.0-litre four-cylinder used across the T5, T6 and T8 has a documented oil consumption issue on earlier production engines. Piston ring design can allow oil into the combustion chamber, and some owners report needing to top up oil between the 15,000 km service intervals.
- Affected: Primarily 2016–2018 T5 and T6 petrol variants; the T6's supercharger adds heat load that can worsen the problem.
- Symptoms: Burning smell, faint blue exhaust smoke under load, oil level dropping noticeably between services.
- Fix: Updated piston ring kits are available and Volvo has issued repair procedures. Check the oil level carefully on inspection — a car recently serviced but already low is a warning sign.
- Rough cost: Piston ring rectification is labour-intensive — allow $2,500–$5,000 at a dealer or Volvo specialist.
Cooling system — hoses and coolant leaks
SPA platform vehicles have a known vulnerability in their coolant plumbing. Forum threads and a Volvo Technical Job (TJ) reference free replacement of specific coolant pipes that develop leaks; bleed hoses and coolant caps have also been flagged. The first sign is often an "Engine Too Hot" warning on the instrument cluster.
- Affected: 2016–2020, all engine variants; T6 higher pressures may accelerate hose wear.
- What to check: Coolant reservoir level and any white residue or dried coolant around hose joints after the car has sat overnight.
- Rough cost: Hose replacement $300–$900. Ignoring a coolant leak risks serious engine damage.
T8 Twin Engine — 12V battery and hybrid system faults
The T8 variant pairs a 400V lithium-ion traction battery with a 12V auxiliary battery charged via a DC-DC converter (not an alternator). When the 12V battery drops too low, the control modules cannot function — which in turn prevents the high-voltage battery from accepting charge, triggering a "Hybrid System Fault" warning and dropping the car into petrol-only mode.
- Fix: Test the 12V battery with a multimeter; a healthy reading is around 12.6V at rest. Replacement is straightforward.
- Rough cost: 12V battery $200–$450 fitted. DC-DC converter replacement $800–$2,000 if that is the cause.
High-voltage traction battery degradation also affects electric range — ask a Volvo dealer to run a battery health report before purchasing any used T8.
PowerPulse system (D5 diesel) — hose failures
The D5 diesel uses Volvo's PowerPulse system — a compressed-air reservoir that injects air into the intake to spool the turbocharger faster. The high-pressure hose between the reservoir and intake is the most common failure point, and some owners report it failing repeatedly even after replacement. EGR hose burn-through is a related weak point on D5 engines.
- Symptoms: Engine warning light, increased turbo lag, fault codes ECM-P24AF96 or ECM-P106515.
- Rough cost: PowerPulse hose $400–$900; EGR hose repair $300–$700.
Air suspension — compressor and air spring failures
Some S90 variants in Australia were fitted with optional air suspension. The two dominant failure modes are a leaking air spring (one corner sits low) and a failed compressor (system disabled entirely). Volvo acknowledged a defect in the compressor's internal valve — caused by residue from a manufacturing anti-corrosive agent — and extended the compressor warranty to seven years on many 2016–2020 SPA platform vehicles including S90/V90 models. It is worth confirming with a Volvo dealer whether your prospective car still qualifies.
- Symptoms: Car sitting low on one corner after overnight parking; "Suspension Service Required" message; harsh ride.
- Rough cost: Air spring per corner $800–$2,200; compressor $1,200–$2,500 (may be covered by extended warranty).
AEB and brake electronics
The S90's AEB system has been the subject of a significant Australian recall (detailed below). Brake squeal on light applications is also widely reported — particularly on T8 models where regenerative braking reduces physical brake use and discs can develop surface rust.
- Brake squeal fix: Anti-vibration compound on pad backs, or pad/disc replacement — $600–$1,400 per axle.
- Note: Any windscreen replacement on a car with forward camera ADAS requires Volvo recalibration; budget an extra $300–$600 on top of glass costs.
Recalls & safety
The S90 has been subject to PRA-administered recalls in Australia. The most significant affected nearly 9,200 Volvo vehicles — including MY19–MY20 S90s — where a missing AEB software line meant the system might not brake automatically for pedestrians, cyclists or certain objects. The fix was a free software update at any Volvo dealer.
A separate recall concerns a second-row seatbelt buckle anchor screw that may loosen on certain models, reducing occupant protection in a collision.
Carify has recall data for the 2018 Volvo S90 — check that page for year-specific safety notices. You can also browse all car problems and recalls or visit the Carify recalls hub.
Buying a used Volvo S90? What to check
- Sensus display: Cold-start and confirm full system load; Bluetooth, audio and nav must all respond without rebooting.
- Oil level: Check immediately on inspection — well below maximum on a recently serviced car suggests consumption issues.
- Coolant hoses: Look for residue or dried coolant around the reservoir and hose joints after overnight parking.
- T8 hybrid: Confirm the car enters EV mode at low speeds; ask for a traction battery health report.
- D5 diesel: Ask specifically about PowerPulse and EGR hose history; any current engine warning light is a red flag.
- Air suspension (if fitted): All four corners must sit level after the car sits overnight; verify extended compressor warranty eligibility.
- Service history: Full Volvo stamps or a reputable independent Volvo specialist matters more here than on a mass-market car — gaps are expensive to investigate.
- History check: Run a VIN check or PPSR check to confirm no outstanding finance, write-off history or odometer irregularities before handing over any money.
The verdict
The Volvo S90 is a distinctive used luxury sedan with genuine build quality, a serene cabin and class-leading safety hardware. Its weak spots — Sensus infotainment glitches, Drive-E oil consumption, coolant plumbing, T8 auxiliary battery complexity and PowerPulse hose fragility on the D5 — are manageable if you know what to look for. Dealer servicing costs are on the higher end, but independent Volvo specialists offer a legitimate alternative without voiding the statutory warranty. Buy with a thorough pre-purchase inspection, a full service history, and a Carify history report — and the S90 can be a rewarding ownership proposition.