Volvo D4/D5 (5 cilindros and VEA)Particulate filter (DPF/FAP)
DPF (particulate filter) blockage and incomplete regenerations on the D4/D5
Why this rating?
Medium severity: It can leave you stranded or get worse if ignored, without destroying the engine.
Frequency common: Fiches-auto.fr records DPF problems in 9 of the 132 testimonies for the first-generation XC60, as well as isolated cases in the second-generation XC90 ("fault fixed by replacing the DPF") and mentions in the S60, where one owner describes the 190 hp D4 as the engine that "accumulates the most EGR, EGR cooler, DPF and AdBlue" issues of the whole page. It appears across several models and generations, although we have not found that Volvo acknowledges it as a design fault with its own campaign.[1][2][3]
Symptoms
- DPF warning light on when the filter clogs or a regeneration is not completed.[2]DPF warning light: other faults that cause it · Garage soon
- Engine warning light linked to a DPF pressure sensor fault.[2]Engine warning light: other faults that cause it · Garage soon
- AdBlue warning grouped with the same emissions faults in some D4 VEA testimonies.[4]AdBlue warning: other faults that cause it · Garage soon
Why it happens
The DPF traps soot from the exhaust and needs to burn it off periodically (regeneration) while the engine runs for a while at a sustained speed; very short, repeated urban journeys prevent the regeneration from completing.[2]
With repeated incomplete regenerations, the filter accumulates soot until it clogs, and the DPF differential pressure sensor can fail and trigger the warning light.[2]
If it is not repaired: A badly clogged DPF means replacing it or having it professionally cleaned, and the car may be left in limp mode with less power until it is fixed.[2]
Affected cars and years
Documented in units of the older 5-cylinder (XC60 2.4 D5 of 215 hp) and of the VEA (XC90 D5 of 225 hp, S60 D4 of 190 hp).[1][2][3]
| Version | Years | Codes |
|---|---|---|
| 2.4/2.0 D3/D4/D5 5-cylinder (D5244T/D5204, 2001-2016) | 2001–2016 | D5244TD5204 |
| 2.0 D2/D3/D4/D5 VEA 4-cylinder (D4204T, 2013-2024) | 2013–2024 | D4204T |
Models fitted with the affected versions
Volvo
- Volvo XC90 I2002–2014
- Volvo XC90 II2015–2024
- Volvo XC60 I2008–2017
- Volvo XC60 II2017–2024
- Volvo S60 I2001–2010
- Volvo S60 II2010–2018
- Volvo V70 III2007–2016
- Volvo S80 II2006–2016
- Volvo XC70 III2007–2016
- Volvo V60 I2010–2019
- Volvo V40 II2012–2019
- Volvo XC402018–2020
- Volvo V60 IIsince 2019
- Volvo V902016–2024
How much it costs to repair
Includes: Diagnosis, cleaning or replacement of the particulate filter and, where appropriate, of the pressure sensor.[2]
We have not found a published quote in Spain for the DPF of this particular engine.
Prices in Spain, including VAT. A workshop hour costs on average €38–66 at independent garages and €77–134 at dealerships in Spain, depending on the region and the brand. How we calculate costs
How to check for it before buying a used car
- Ask whether the car is used mainly in town on short journeys, and whether it has had DPF warnings.
- Take a long test drive at a sustained speed to check whether the DPF warning light comes on or whether the car forces a regeneration.
Parts needed
The part or kit that fixes this fault, according to the sources.
Particulate filter (DPF)
Traps soot from the diesel exhaust; replaced or cleaned if it becomes irreversibly clogged.
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How to prevent it
- Take a long road trip every now and then so the DPF can complete its regeneration, especially if the car is used a lot in town.
- Do not ignore the DPF warning light: continuing to drive with repeated forced regenerations speeds up its clogging.
Recalls, campaigns and claims
As of 27 September 2026, we have no record of recalls, campaigns or extended manufacturer warranties for this fault. Check with an official dealer using the chassis (VIN) number: they will tell you whether the car has any outstanding campaign.
What owners say
Frequently asked questions
Why does the DPF on the Volvo D4/D5 clog?
Mostly because of short urban journeys that do not allow the regeneration (burning off the accumulated soot) to complete, so the filter gradually clogs over time.[2]
How many DPF cases are documented?
Fiches-auto.fr records 9 DPF cases among 132 testimonies for the first-generation Volvo XC60, as well as isolated cases in the XC90 and S60 with the VEA engine.[1][2][3]
Are the DPF and AdBlue warnings related?
In some D4 VEA testimonies they appear grouped together with the EGR as the engine's most repeated set of emissions faults, although they do not always share the same cause.[4]
What can you do now?
We will put you in touch with a partner only if you authorise it in the form.
Other D4/D5 faults
- Critical severityFrequency: CommonTimingAuxiliary belt breakage that takes the timing belt with it (5-cylinder)Yes: on the 2.4/2.0 5-cylinder (D5244T/D5204, 2001-2016), several owners describe the auxiliary belt breaking and taking out or damaging the timing belt, with the engine destroyed. It happens in the S60 and XC60 between 74,000 and 119,000 km, and in one case not even the extended warranty covered it.
- High severityFrequency: CommonLubricationHigh oil consumption from 90,000-150,000 km that harms the turbo (VEA)On the 190 hp VEA D4, several owners document oil consumption that soars from 90,000-150,000 km (up to 1 litre per 1,000 km in one case), and Fiches-auto.fr warns that this lack of lubrication can end up damaging the turbo. It describes it as "the most sensitive engine" on the Volvo V60 page.
- Medium severityFrequency: CommonEmissions controlClogged EGR valve or EGR cooler leaking into the intakeYes, in both D4/D5 families: the EGR gets dirty or clogged, and its cooler can lose its seal and leak coolant into the intake. It appears in the XC60, S60, V40 and V60, between 56,000 and 180,000 km, with limp mode and, in some cases, several valve replacements.
- Medium severityFrequency: OccasionalTurboDamaged charge air hose or pipe on the Volvo D4On the Volvo 2.0 D4 diesel an intercooler hose can be damaged, and on the 2010-2013 V60 a pipe bracket made it rub against the pulley (P0299, loss of power). Volvo corrected it with a service action and modified parts.
- Medium severityFrequency: RareIntakeBreakage of the intake manifold swirl flap (5-cylinder)One documented case in the first-generation Volvo XC60 (2.4d of 163 hp) describes replacement of the intake manifold swirl flap at 120,000 km. With the sources available we have only been able to confirm that specific case for this engine, so we cannot say it is widespread.
More faults with the particulate filter on other engines and cars
- High severityFrequency: Very frequentOM651EGR and particulate filter clogging, and emissions software updatesThe particulate filter and EGR clog up with short journeys, as on any diesel with these systems. In addition, Germany's KBA required software updates on several models with this engine between 2018 and 2021 because of a function that reduced EGR outside a temperature range.Repair (garage): €800–€2,500
- High severityFrequency: Common1.3 MultijetIncomplete particulate filter regenerations and oil dilutionIn heavy urban use, with short journeys that do not let the particulate filter regeneration finish, unburnt diesel passes into the sump and dilutes the oil; the level can rise on the dipstick and the oil loses its ability to lubricate. Repeated many times, it speeds up engine wear.
- High severityFrequency: Common2.0 HDiDPF clogging on additive-type systems (Eolys/cerine)The additive-type diesel particulate filter (DPF) of the 2.0 HDi clogs relatively easily on short journeys, especially on the 107/110 and 136-140 hp versions. The anti-pollution warning light comes on and, if ignored, the car loses power and may end up needing a new DPF.
- High severityFrequency: Common1.6 and 2.0 MultiJet IISaturated diesel particulate filter (DPF) from incomplete regenerationsIn urban use with short journeys, the particulate filter does not manage to complete its regeneration and becomes saturated; garages recommend a weekly motorway run to avoid it. The filter itself is among the weak points flagged in the 1.6 and 2.0 MultiJet II after a certain mileage.
- High severityFrequency: Common2.0 Ingenium diéselFuel dilution of the oil linked to particulate filter regenerationsYes: on short trips and in urban use, the Ingenium diesel's particulate filter does not always complete regeneration, and some of the diesel injected to burn off the soot ends up mixing with the engine oil, which reduces its ability to lubricate.
- High severityFrequency: CommonMZR-CDOil dilution from leaking injector seals and DPF regenerationsOn the 2.0 and 2.2 MZR-CD, injector seals that age badly and incomplete particulate filter regenerations on short journeys can let unburnt diesel into the sump, diluting the oil and leaving the engine with less lubrication.
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Sources
Every fact on this page links to its source. If you find an error, let us know.
- Fiabilité et pannes Volvo XC90 2Fiches-auto.fr · Other source · consulted 27 September 2026 · in French
- Fiabilité et pannes Volvo XC60 (2008-2017)Fiches-auto.fr · Other source · consulted 27 September 2026 · in French
- Fiabilité et pannes Volvo S60Fiches-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