The second-generation Volvo XC90 arrived in Australia in 2015 as a large, premium seven-seat SUV built on Volvo's Scalable Product Architecture (SPA) platform. It ditched the old V6 and V8 for a line-up of 2.0-litre Drive-E four-cylinder engines — the T5 (turbocharged), T6 (twin-charged), T8 (plug-in hybrid twin-charged) and, in early years, the D5 diesel — paired with an eight-speed automatic. Critically acclaimed for its design, safety technology and interior quality, it nonetheless has a used-market reputation as a car that rewards careful ownership and punishes neglect. Dealer servicing is expensive, complexity is high, and several known issues can turn an uninspected purchase into a costly mistake.
Sensus infotainment system: freezes, reboots and slow response
The large central touchscreen running Volvo's Sensus Connect system is one of the XC90's defining features — and one of its most commonly reported fault areas. Across 2015–2018 models, owners report the centre display freezing, going black, rebooting mid-drive or becoming sluggish. Affected functions include audio, navigation, Bluetooth, rear parking sensors and climate — all routed through Sensus. Some owners describe spontaneous reboots every couple of weeks; others see it lock up for minutes.
The cause is usually software rather than hardware. Volvo has issued multiple firmware updates; dealers can apply them at a service visit. A soft reset (holding the home button for 20–30 seconds) resolves minor freezes; a 12V battery disconnect for 15–30 minutes clears more stubborn faults. On rare occasions the central electronic module (CEM) is the underlying culprit. Always confirm a used XC90's Sensus software is current before buying.
Engine oil cooler: oil-and-coolant contamination
A well-documented fault across 2015–2021 Volvos running the 2.0-litre VEA engine — which covers virtually every XC90 T5, T6 and T8 sold in Australia — is failure of the engine oil cooler. When the cooler springs an internal leak, oil and coolant mix into a milky sludge that contaminates both circuits. If undetected, the result can be catastrophic engine damage from overheating or oil starvation.
Warning signs include a dropping coolant level with no visible external leak and a milky residue under the oil filler cap. If either appears, stop driving immediately. Fix involves replacing the cooler and performing multiple system flushes. Volvo has acknowledged the fault through internal technical journals but has not issued a formal recall. Expect roughly $1,500–$2,500 at a dealer for the repair and full decontamination.
Coolant bleeder hose cracking (recall-related)
The small coolant bleeder hose on petrol XC90s is also prone to cracking, allowing coolant to accumulate in the catalytic converter heat shield — a fire risk. Volvo issued recall campaign R29936 in 2019 covering petrol-engine XC90s built June 2015–April 2019. A separate recall (R29904) covered fuel hose cracking on 2015–2016 models. Both involve dealer inspection and free part replacement. Confirm both campaigns have been closed out on any car you are considering.
Timing belt: service item that many buyers overlook
Unlike many modern engines, the Drive-E 2.0-litre uses a timing belt — not a chain. The supercharger drive and high-pressure fuel pump both run off it in T6 and T8 variants, making it an engineering necessity. Volvo specifies replacement around 240,000 km or 10 years, whichever comes first, though some independent specialists prefer a more conservative interval in Australian conditions. The belt, tensioners and idler pulleys should be replaced as a set; a failure on this interference engine causes serious internal damage. Always confirm the belt's replacement status when reviewing a higher-kilometre used XC90.
T8 plug-in hybrid: 12V battery and hybrid system faults
The XC90 T8 combines the twin-charged petrol engine with a rear electric motor and floor-mounted lithium-ion pack. Its 12V auxiliary battery — which powers the electronics and starts the car — is charged entirely from the 400V traction battery rather than a conventional alternator. When the 12V battery degrades or the charging circuit faults, owners see warnings including "12V battery charging fault," "Hybrid system failure" or "Reduced performance," and in some cases the car will not start. Some 2015–2017 T8 owners report unexplained parasitic drain that kills a fresh 12V battery within hours; deeper diagnosis of the CEM or hybrid charging circuit requires Volvo-trained technicians and specialist equipment. Have the full hybrid system — including charging function and electric-only range — tested before purchase.
Air suspension compressor (Inscription and optioned models)
Some XC90s — particularly Inscription trims — were fitted with optional air suspension. A known weakness is the air compressor, which can fail and cause the car to sag at one or more corners or trigger "Service Required" warnings. Volvo acknowledged the prevalence of this fault and extended the warranty on the air compressor for 2016–2020 XC90s to seven years with unlimited kilometres from the original in-service date. If a car you're considering still falls within that window, check eligibility with a Volvo dealer. Outside warranty, compressor replacement can run $1,000–$2,000 or more, and air spring replacement adds further cost.
Sunroof drain and water ingress
Multiple owners of 2015–2017 XC90s with panoramic sunroofs have reported water leaking into the rear cabin, pooling in the boot or soaking the rear headliner. The typical cause is blocked sunroof drain tubes or a degraded drain fitting; when the car is parked on an incline in heavy rain, water overflows the sunroof tray and finds its way inside. Volvo issued technical bulletin RTJ-31272 covering sunroof seal replacement, and some dealers have fitted a redesigned tray. Left unaddressed, the ingress can damage the boot floor, promote mould and — on T8s — raise concerns about moisture near electrical components. Check the boot carpet and headliner carefully during any inspection.
Recalls & safety
The 2015–2018 XC90 has been subject to multiple PRA recalls in Australia. Confirmed campaigns include airbag-related recalls affecting 2016–2017 models (curtain airbag inflation, igniter adequacy, bolt retention), a seatbelt pre-tensioner fault on 2017 seven-seat models, an air conditioning drainage hose issue on 2016–2017 vehicles, and the fuel hose and coolant bleeder hose campaigns covering 2015–2019 petrol models. Check year-specific details on Carify: 2015, 2016, 2017 and 2018. The recalls landing page also covers Volvo-wide recall history.
Buying a used Volvo XC90? What to check
- Service history: Volvo recommends servicing every 12 months or 15,000 km. Gaps are a significant red flag given the oil cooler and timing belt risks.
- Timing belt record: Confirm replacement status — or factor in the cost if the car is approaching or past the interval.
- Oil and coolant: Look for milky residue under the filler cap and discolouration in the coolant reservoir — signs of oil-cooler contamination.
- Sensus software: Confirm any outstanding firmware updates have been applied at a Volvo dealer.
- T8 hybrid system: Test plug-in charging, check the 12V battery holds charge, and review any stored fault codes.
- Air suspension (if fitted): Inspect corners for sag, listen for the compressor at start-up, and check for "Service Required" messages.
- Boot and headliner: Check for moisture or musty smells — evidence of sunroof drain problems.
- Recall status: Ask a Volvo dealer to confirm all open campaigns have been completed on the specific VIN.
- History check: Run a PPSR check and a VIN check to confirm no finance, write-offs or odometer issues before committing.
Dealer servicing costs are genuinely steep — owners regularly report $700–$1,200 per scheduled service. Independent Volvo specialists exist in most capital cities and offer a cost-effective alternative without voiding statutory warranty rights.
The verdict
The second-generation XC90 is a genuinely well-built large luxury SUV that rewards careful ownership. Its known weaknesses are real but manageable: Sensus glitches respond to software updates, the oil cooler issue is detectable early, the timing belt is a straightforward service item if done on schedule, and most recalls on higher-kilometre cars have already been completed. The T8 adds complexity but real running-cost benefits for the right buyer. A thorough pre-purchase inspection, full service history and a Carify history check will cut most of the risk out of buying one — and give you solid negotiating leverage if anything is outstanding.