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Volvo S90 Problems & Known Issues

The most common Volvo S90 problems ranked by severity — what to watch for, what it costs to fix, and what happens if you ignore it.

Generations

SPA — Second Generation (SPA Platform)
2016–2024
2.0 D4/D5, 2.0 T4/T5/T6, 2.0 T8 Twin Engine

Top issues to watch for

The most serious Volvo S90 problems ranked by severity. 4 known issues ranked by how much damage they can do.

Major
Front suspension ball joint wear (SPA)
SPA2016–202420k–40k miles
MOT data shows diesel variants fail ball joint tests at 4.3x the fleet average rate, typically between 20,000-40,000 miles. The additional weight of the diesel engine and battery system on hybrid variants places higher loads on the front suspension ball joints than the suspension geometry was originally calibrated for. This is a safety-critical failure mode that affects steering control.
What happens if ignoredA failed ball joint can separate completely, causing immediate loss of steering control and wheel alignment. The car should not be driven if ball joint failure is confirmed. Replacement typically requires professional alignment afterward.
Independent garage
£200–£350
Specialist
£280–£450
Main dealer
£400–£650
Parts only
£60–£120
Major
Turbocharger oil feed pipe leak (SPA)
SPA2016–202440k–80k miles
The high-pressure oil feed pipe to the turbocharger develops leaks at the banjo bolt connections, particularly where the pipe connects to the turbocharger housing. This is widely reported across Volvo forums for the SPA platform engines. Oil starvation can destroy the turbocharger bearing within minutes of driving, making this a critical failure mode requiring immediate attention.
What happens if ignoredOil starvation destroys the turbocharger bearing assembly, requiring complete turbocharger replacement at £2,000-4,000. The car should not be driven if active oil leakage is visible around the turbocharger. Continued driving risks engine damage from oil loss.
Independent garage
£300–£500
Specialist
£400–£700
Main dealer
£600–£1,000
Parts only
£80–£200
Major
DPF regeneration failure (SPA)
SPA2016–202415k–60k miles
The diesel particulate filter becomes blocked on vehicles used primarily for short journeys or city driving where regeneration cycles cannot complete naturally. The SPA platform DPF system is particularly sensitive to incomplete regeneration cycles, leading to progressive blockage and eventually requiring expensive cleaning or replacement. This is a documented issue across Volvo diesel forums.
What happens if ignoredComplete DPF blockage puts the car into limp mode with severely restricted performance. DPF replacement costs £1,500-2,500. Professional cleaning costs £300-600 but is not always successful on heavily contaminated filters.
Independent garage
£300–£600
Specialist
£400–£800
Main dealer
£600–£1,200
Parts only
£200–£400
Minor
Premature brake pad wear (SPA)
SPA2016–20240k–60k miles
The large 19-inch wheel and brake package fitted as standard creates higher brake temperatures and pad consumption than typical executive saloons. Front pads commonly need replacement by 25,000-30,000 miles under normal driving conditions.
What happens if ignoredWorn brake pads damage the brake discs if not replaced promptly. Disc replacement adds £400-800 to the repair cost. The car remains safe to drive with moderate pad wear but should be inspected immediately if grinding noises are heard.
Independent garage
£180–£280
Specialist
£220–£350
Main dealer
£300–£450
Parts only
£80–£150

MOT failure hotspots

Based on DVSA MOT test data. These are the items where the Volvo S90 fails at a significantly higher rate than the average car.

Headlight fault
Lights & Electrics · 20-40k miles
MOT failure rate: 9.2x the fleet average
Sample: 4,015 tests

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Related

Volvo S90 reliability FAQs

What are the most common problems with the Volvo S90?

The Volvo S90 has 4 known issues across 2 severity levels. The most common problems relate to Front suspension ball joint wear (SPA) and Turbocharger oil feed pipe leak (SPA).

Is the Volvo S90 reliable?

The Volvo S90 has 0 dangerous and 3 major known issues. No dangerous issues are tracked, which is a positive sign.

How much does it cost to fix Volvo S90 problems?

Repair costs range widely. The most significant issue (Front suspension ball joint wear (SPA)) costs £200–£350 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.