D4/D5 vs 2.5 TDI R5: which engine is more reliable?

According to our risk index, the 2.5 TDI R5 carries less risk than the D4/D5: 45/100 (moderate risk) versus 64/100 (high risk). The D4/D5 has 2 documented serious faults, the main one being «Auxiliary belt breakage that takes the timing belt with it (5-cylinder)»; the 2.5 TDI R5 has 2 documented serious faults, the main one being «Plasma coating flaking off the cylinders».

Risk index

D4/D5

High risk · 2 serious faults

Risk index

2.5 TDI R5

Moderate risk · 2 serious faults

Lower risk

The index (0–100) weights the severity and frequency of the three most serious documented faults. How it is calculated

Reviewed on 5 October 202613 sources How we work

Is the D4/D5 reliable?

The Volvo D5/D4 covers two different engines: the classic 5-cylinder (2001-2016, D5244T/D5204) and the 4-cylinder VEA (D4204T, from 2013). On the former, several owners document the auxiliary belt breaking and taking the timing belt with it, destroying the engine; on the VEA the most common problems are the EGR, the DPF and oil consumption that can damage the turbo from 90,000-150,000 km. Neither is an engine to buy without checking its service history.^[1][2][3][4]

See the 6 of the D4/D5 faults

Is the 2.5 TDI R5 reliable?

The 2.5 TDI R5 in the T5 and the Touareg has a poor reputation: camshaft wear, pump injectors and cylinder coating. The later series were more reliable. It is not Audi's V6 TDI.^[5][6][7]

See the 5 of the 2.5 TDI R5 faults

Side-by-side comparison

Comparison of D4/D5 and 2.5 TDI R5
Item	D4/D5	2.5 TDI R5
Technical data
Type	Engine	Engine
Fuel	Diesel	Diesel
Displacement	—	2,461 cm³
Timing	Timing belt (dry)	Timing belt (dry)
Power	120–235 hp	88–174 hp
Production	2001–2024^[1][2][8]	2003–2011^[9][10][11]
Reliability
Risk index (what is it?)	64High risk	45Moderate risk
Documented faults	6	5
Of high or critical severity	2	2
Worst severity	Critical severity	Critical severity
Main faults	Critical severity: Auxiliary belt breakage that takes the timing belt with it (5-cylinder) High severity: High oil consumption from 90,000-150,000 km that harms the turbo (VEA) Medium severity: Clogged EGR valve or EGR cooler leaking into the intake	Critical severity: Plasma coating flaking off the cylinders High severity: Camshaft and hydraulic tappet wear Medium severity: Leaks and play in the unit injectors
Most expensive documented repair	No reliable data	No reliable data
Which versions to buy
BuyRecommended versions	None	None
With cautionVersions to be cautious about	2.4/2.0 D3/D4/D5 5-cylinder (D5244T/D5204, 2001-2016)^[3][12] 2.0 D2/D3/D4/D5 VEA 4-cylinder (D4204T, 2013-2024)^[3][4][13]	2.5 TDI 130 and 174 hp with DPF (BNZ, BPC, 2006-2009)^[5] 2.5 TDI common rail Crafter (88 to 163 hp, 2006-2011)^[11]
AvoidVersions to avoid	None	2.5 TDI 130 and 174 hp (AXD, AXE, 2003-2006)^[5]

Severity of each fault: green, low; amber, medium; red, high; dark red, critical. How we rate them

Cars that each one is fitted to

D4/D5

See the 14 models with the D4/D5

2.5 TDI R5

Other comparisons

With the D4/D5

With the 2.5 TDI R5

Compare other engines

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Sources

Every fact on this page links to its source. If you find an error, let us know.

Volvo Engine ArchitectureWikipedia · Other source · consulted 27 September 2026
Volvo D5: 185 CV para el S60, V70, XC70 y XC90Autopista.es · Motoring press · published July 2005 · consulted 27 September 2026 · in Spanish
Fiabilité et pannes Volvo XC60 (2008-2017)Fiches-auto.fr · Other source · consulted 27 September 2026 · in French
Fiabilité et pannes Volvo V60Fiches-auto.fr · Other source · consulted 27 September 2026 · in French
VW T5 4Motion Gebrauchtwagen-TestAuto Bild · Motoring press · consulted 5 October 2026 · in German
Kaufberatung gebrauchter VW T5 (2003-2015)Promobil · Motoring press · consulted 5 October 2026 · in German
Ratgeber Technik: Fehler VW T5Auto Bild · Motoring press · consulted 5 October 2026 · in German
Volvo XC90Wikipedia · Other source · consulted 27 September 2026 · in Spanish
VW T5Wikipedia (de) · Other source · consulted 5 October 2026 · in German
VW Touareg IWikipedia (de) · Other source · consulted 5 October 2026 · in German
Volkswagen CrafterWikipedia (es) · Other source · consulted 5 October 2026 · in Spanish
Fiabilité et pannes Volvo S60Fiches-auto.fr · Other source · consulted 27 September 2026 · in French
Fiabilité et pannes Volvo XC60 (2017-)Fiches-auto.fr · Other source · consulted 27 September 2026 · in French