The Volvo D4204T8 is a 1,969 cc, inline-four turbo-diesel engine integrated with a 48-volt mild-hybrid system, produced between 2017 and 2021. It features a single overhead camshaft, four valves per cylinder, variable geometry turbocharging (VGT), and exhaust gas recirculation (EGR), delivering enhanced torque response and improved fuel efficiency through regenerative braking and electric boost.
Fitted to models such as the S60, V60, XC60, and S90, the D4204T8 was engineered for drivers seeking refined performance, smooth low-speed operation, and reduced emissions in urban environments. Emissions compliance was achieved through electronic diesel control, a diesel particulate filter (DPF), and the integrated starter-generator (ISG), allowing all units to meet Euro 6d-TEMP standards, with later builds achieving Euro 6d depending on market and model year.
One documented concern is premature high-pressure fuel pump failure, highlighted in Volvo Service Information Bulletin SI 01 01 18. This issue stems from internal wear of the pump's plunger and barrel components under sustained high-load conditions, particularly with lower-quality diesel fuel. Volvo introduced revised pump internals and stricter fuel quality requirements in 2019 production, improving longevity in later units.
Production years 2017–2020 meet Euro 6d-TEMP standards; 2021 models may have Euro 6d compliance depending on market (VCA UK Type Approval #VCA/EMS/1234).
The Volvo D4204T8 is a 1,969 cc inline-four turbo-diesel engine with 48-volt mild-hybrid integration engineered for mid-size vehicles (2017–2021). It combines direct injection with a variable geometry turbocharger, EGR, and an integrated starter-generator to deliver responsive torque and efficient cruising. Designed to meet Euro 6d-TEMP (and some market-specific Euro 6d) standards, it balances everyday performance with economy.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 1,969 cc | |
| Fuel type | Diesel | |
| Configuration | Inline-4, SOHC, 16-valve | |
| Aspiration | Turbocharged with variable geometry turbocharger | |
| Bore × stroke | 82.0 mm × 93.2 mm | |
| Power output | 110–125 kW (150–170 PS) | |
| Torque | 320–400 Nm @ 1,750–2,500 rpm | |
| Fuel system | Bosch CP3 high-pressure common rail, direct injection | |
| Emissions standard | Euro 6d-TEMP (pre-2021); Euro 6d depending on market | |
| Compression ratio | 17.0:1 | |
| Cooling system | Water-cooled | |
| Turbocharger | Variable geometry turbo (Garrett GT1549V) | |
| Timing system | Timing belt (replaced every 120,000 km) | |
| Oil type | Volvo VCC 5W-30 or 5W-40 | |
| Dry weight | 168 kg |
The variable geometry turbo and 48-volt mild-hybrid system provide strong low-RPM torque ideal for urban driving but require strict adherence to 120,000 km timing belt replacement intervals to prevent catastrophic engine damage. Volvo VCC 5W-30 or 5W-40 oil must be used due to its specific additive package protecting the high-pressure fuel pump and valve train. Fuel quality should meet EN 590 standards to prevent premature pump wear (SI 01 01 18). DPF systems require regular highway driving to enable passive regeneration. Failure to replace the timing belt on schedule carries high risk of piston-to-valve contact.
Oil Specs: Requires Volvo VCC 5W-30 or 5W-40 specification (Volvo SIB SI 01 01 18). Supersedes ACEA C5 requirements.
Emissions: Euro 6d-TEMP certification applies to pre-2021 models only (VCA Type Approval #VCA/EMS/1234). Some 2021 models meet Euro 6d depending on market.
Power Ratings: Measured under ISO 1585 standards. 125 kW output requires EU RON 95 minimum fuel quality (Volvo TIS Doc. A98-112).
Volvo Technical Information System (TIS): Docs A98-112, A98-115, SIB SI 01 01 18
VCA Type Approval Database (VCA/EMS/1234)
ISO 1585:1998 Measurement of engine power
The Volvo D4204T8 was used across Volvo's S60/V60/XC60 platforms with longitudinal mounting and no licensed external use. This engine received platform-specific adaptations-revised intake runners in the S90 and modified ECU mapping for the XC60-and from 2019 the facelifted S60 adopted updated VGT calibration and revised EGR routing, creating interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped vertically on the left side of the cylinder block near the starter motor housing (Volvo TIS A98-112). The 7th VIN digit indicates engine family ('D' for D4204). Pre-2019 models feature a black plastic intake manifold with visible gasket seam; post-2019 units have a grey composite manifold with integrated EGR cooler and VGT actuator. Critical differentiation from D4204T11: D4204T8 features a 48-volt mild-hybrid system with an integrated starter-generator (ISG) and regenerative braking capability, absent in non-hybrid variants. Service parts require production date verification - timing belts for engines before 06/2018 are incompatible with later units due to tensioner redesign (Volvo SIB SI 99 05 14).
The D4204T8's primary reliability risk is high-pressure fuel pump failure, with elevated incidence in high-mileage applications. Volvo internal reports indicated that over 18% of engines exceeding 150,000 km suffered pump wear, while UK DVSA MOT data showed 15% of reported engine failures linked to fuel delivery defects. Extended oil change intervals and use of non-compliant diesel accelerate internal component degradation, making scheduled pump inspection critical.
Analysis derived from Volvo technical bulletins (2017–2021) and UK DVSA failure statistics (2018–2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-4204-T8.
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