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Volvo Xc90 (First Generation)

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Volvo XC90 (First Generation: 2003-2014) - A Comprehensive Guide

The first-generation Volvo XC90, launched in 2002 as a 2003 model, marked Volvo's entry into the competitive luxury SUV market. Built on the P2 platform (shared with models like the S60 and V70), the XC90 aimed to combine Volvo's renowned safety with the practicality and versatility of an SUV. It quickly became one of Volvo's best-selling models, appealing to families and those seeking a comfortable and safe vehicle with available all-wheel drive.

Generations

First Generation (2003-2014)

The first generation XC90 remained largely unchanged throughout its production run, receiving several facelifts and mechanical updates. Key changes and model year milestones include:

  • 2003: Initial launch with 2.5T (turbocharged 5-cylinder) and T6 (twin-turbocharged 6-cylinder) engines.
  • 2005: Introduction of the 4.4L V8 engine (developed by Yamaha) and a minor interior refresh. The 2.5T received some minor tuning.
  • 2007: Facelift including revised headlights, taillights, and grille. Interior updates included improved materials and a revised center console. Addition of the 3.2L inline-6 engine as a replacement for the aging T6.
  • 2010: Minor exterior revisions, including body-colored lower cladding.
  • 2012: Further subtle exterior updates, including LED daytime running lights.
  • 2014: Final production year of the first-generation XC90.

Reliability & Common Issues

While the first-generation XC90 is generally a reliable vehicle, certain issues are more prevalent. Careful inspection and maintenance records are crucial when considering a used model. Here's a detailed breakdown:

Engine Issues:

  • 2.5T (B5254T2/T7):
    • Turbocharger problems: Oil leaks and bearing failures can occur, especially in poorly maintained examples. Listen for whining or unusual noises from the turbo.
    • PCV system clogging: The positive crankcase ventilation (PCV) system can become clogged, leading to increased crankcase pressure, oil leaks (especially around the rear main seal), and even blown seals. Look for oil leaks and check the condition of the PCV system.
    • Coil Pack Failures: Often misdiagnosed. Can cause rough running and misfires.
  • T6 (B6294T):
    • Transmission failures (GM 4T65E): This transmission is a known weak point, particularly with the added torque of the T6 engine. Look for slipping, rough shifting, and delayed engagement. Regular transmission fluid changes are essential. Many were replaced under warranty.
    • Turbocharger issues: Similar to the 2.5T, but with two turbos, the potential for issues is doubled.
  • 3.2L (B6324S):
    • Oil consumption: Some 3.2L engines can consume excessive oil. Monitor oil levels regularly.
    • Timing chain issues: Though less common than on some other engines, timing chain stretch and related issues can occur, leading to rough running and potential engine damage. Listen for rattling noises, especially on startup.
    • Variable Valve Timing (VVT) Solenoid Issues: These can fail and cause rough idling and poor performance.
  • 4.4L V8 (B8444S):
    • Counterbalance Shaft Bearing Failure: This is arguably the most serious and expensive problem. The engine needs to be removed from the car to repair. Listen for knocking noises at idle. Ignoring this issue will lead to catastrophic engine damage. This is the V8's Achilles heel.
    • Alternator placement: Located low on the engine, it is prone to damage from water ingress.

Transmission Issues:

  • As mentioned above, the GM 4T65E transmission in the T6 model is particularly susceptible to failure. Regardless of engine, regular transmission fluid changes (using the correct fluid specification) are crucial for longevity.
  • Valve body issues can occur in the Aisin Warner transmissions used with the other engines.

Suspension & Steering Issues:

  • Front suspension components: Ball joints, control arm bushings, and tie rod ends are prone to wear and tear, especially on vehicles driven on rough roads.
  • Rear self-leveling suspension (Nivomat): These shocks can fail and are expensive to replace. Consider converting to standard shocks if the self-leveling function is not required.
  • Power steering pump failures: Listen for whining noises from the pump, especially when turning the steering wheel.

Electrical Issues:

  • Climate control issues: The electronic climate control (ECC) module can develop problems, leading to erratic temperature control.
  • Sunroof leaks: Clogged sunroof drains can lead to water leaks into the cabin.
  • Rear Electronic Module (REM) Issues: This module controls various rear functions. Failures can cause problems with lights, parking sensors, and other systems.

Other Common Issues:

  • Rust: Check for rust, particularly around the wheel arches, door bottoms, and undercarriage. Vehicles from colder climates are more susceptible.
  • Interior wear: Check for wear and tear on the seats, carpets, and dashboard. Leather upholstery can crack and fade over time.

Driving Experience

The first-generation XC90 offers a comfortable and composed driving experience, prioritizing safety and practicality over sporty handling. Here's a breakdown:

Pros:

  • Comfortable ride: The XC90 excels at providing a smooth and comfortable ride, making it well-suited for long journeys.
  • Spacious interior: The three-row seating configuration provides ample space for passengers and cargo.
  • Safety features: The XC90 is equipped with a comprehensive suite of safety features, including side airbags, curtain airbags, and Volvo's renowned whiplash protection system (WHIPS).
  • Available all-wheel drive: The AWD system provides enhanced traction in slippery conditions.
  • Solid Build Quality: Despite some known issues, the car feels well built and durable.

Cons:

  • Handling: The XC90 is not a particularly sporty vehicle. Body roll is noticeable in corners, and the steering can feel somewhat numb.
  • Fuel economy: Fuel economy is not a strong point, especially with the V8 and T6 engines.
  • Turning Radius: The car has a relatively wide turning radius, making parking in tight spaces challenging.
  • Some Engine/Transmission Combinations Troublesome: As detailed above, certain engine and transmission combinations have a higher risk of failure.

Buying Advice

When buying a first-generation XC90, consider the following:

  • Years to look for: 2007 and newer models are generally preferred due to the facelift, updated interior, and the replacement of the problematic T6 engine with the 3.2L inline-6. However, the 3.2L still has its own issues, as mentioned.
  • Years to avoid (or approach with caution): The T6-powered models (2003-2006) are generally best avoided unless the transmission has been replaced or rebuilt. The V8 models (2005-2014) require careful inspection for counterbalance shaft bearing issues.
  • Engine Choice:
    • 2.5T: A decent compromise between performance and fuel economy. Good reliability, but check for turbocharger and PCV issues.
    • 3.2L: Generally more reliable than the T6, but oil consumption and timing chain issues should be considered.
    • 4.4L V8: Powerful and smooth, but the counterbalance shaft bearing issue is a major concern. Pre-purchase inspection by a Volvo specialist is highly recommended.
  • Maintenance records: Look for a vehicle with complete and detailed maintenance records. Evidence of regular oil changes, transmission fluid changes, and other preventative maintenance is crucial.
  • Pre-purchase inspection: Have the vehicle inspected by a qualified mechanic, preferably one with experience working on Volvos. Pay particular attention to the engine, transmission, suspension, and brakes. Specifically request inspection for counterbalance shaft bearing wear if considering a V8.
  • Check for recalls: Verify that all applicable recalls have been performed.
  • Test drive thoroughly: Pay attention to the engine performance, transmission shifting, suspension feel, and brake performance. Listen for any unusual noises or vibrations. Test all electrical components to ensure they are working properly.
  • Consider the price: The price should reflect the vehicle's condition, mileage, and maintenance history. Be prepared to pay more for a well-maintained example. Remember, cheaper isn't always better in the long run.
  • AWD Verification: Confirm the AWD system functions correctly, especially important if you require it. Find a loose surface and confirm all wheels receive power.

By carefully considering these factors, you can increase your chances of finding a reliable and enjoyable first-generation Volvo XC90 that meets your needs.

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