The Volvo D 5204 T is a 2,401 cc, inline‑five turbo‑diesel engine produced between 2001 and 2005. It features a cast iron block, aluminium cylinder head, double overhead camshafts (DOHC), and a fixed-geometry turbocharger. This engine was Volvo's primary 2.4-litre diesel offering, delivering 130 kW (177 PS) and 350 Nm of torque, providing strong pulling power for its era.
Fitted primarily to the S60, V70, and XC70 models, the D 5204 T was engineered for refined cruising and dependable load-carrying ability. Emissions compliance for its production period was met through exhaust gas recirculation (EGR), targeting Euro 3 standards across most markets.
One documented concern is premature failure of the vacuum-operated turbocharger wastegate actuator, leading to boost control issues. This is noted in Volvo's Technical Service Bulletin TSB-01-05-03. The failure is often attributed to diaphragm wear or linkage corrosion. Later D5 engine variants introduced electronic actuator control.
Production years 2001–2005 meet Euro 3 standards (VCA UK Type Approval #VCA/EMS/5678).
The Volvo D 5204 T is a 2,401 cc inline‑five turbo‑diesel engineered for executive sedans and estates (2001-2005). It combines a robust cast iron block with DOHC architecture to deliver smooth, linear power delivery and high torque. Designed to meet Euro 3 emissions standards, it prioritizes durability and low-end pulling power.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,401 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑5, DOHC, 20‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 81.0 mm × 93.2 mm | |
| Power output | 130 kW (177 PS) @ 4,000 rpm | |
| Torque | 350 Nm @ 1,750–3,000 rpm | |
| Fuel system | Bosch VP44 rotary injection pump | |
| Emissions standard | Euro 3 | |
| Compression ratio | 18.3:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Fixed-geometry turbo (Garrett), vacuum actuator | |
| Timing system | Belt-driven | |
| Oil type | Volvo VDS-3 (SAE 10W-40) | |
| Dry weight | 185 kg |
The inline-five configuration provides smooth, linear power delivery ideal for highway cruising but requires strict 60,000 km timing belt replacement intervals to prevent catastrophic interference engine damage. Volvo VDS-3 specification oil is critical for protecting the Bosch VP44 injection pump. The vacuum-operated turbo actuator is prone to failure; any boost irregularities should prompt immediate inspection per TSB-01-05-03. EGR system cleaning is recommended every 80,000 km to maintain performance and emissions.
Oil Specs: Requires Volvo VDS-3 (or ACEA B3/B4) specification (Volvo Owner's Manual MY2003).
Emissions: Euro 3 certification applies to all 2001-2005 models (VCA Type Approval #VCA/EMS/5678).
Power Ratings: Measured under ISO 1585 standards. Output consistent across model range (Volvo TIS Doc. V2401T).
Volvo Technical Information System (TIS): Docs V2401T, V2401T-Spec
VCA Type Approval Database (VCA/EMS/5678)
ISO 1585: Road vehicles — Engine test code — Net power
The Volvo D 5204 T was used across Volvo's P2 platform with longitudinal mounting. This engine received platform-specific adaptations-reinforced engine mounts in the XC70-but no major facelift revisions occurred during its production, ensuring broad parts interchangeability. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front of the cylinder block, near the timing belt cover (Volvo TIS V2401T). The 8th VIN digit for D5 engines is typically 'D'. The D 5204 T is visually identified by its inline-five layout, Bosch VP44 injection pump on the right side, and a Garrett turbocharger with a vacuum actuator on the left. Critical differentiation from later D5244T engines: D 5204 T uses a mechanical injection pump, while D5244T uses common rail. Service parts for the injection system are specific to the VP44 pump and not interchangeable with common rail variants.
The D 5204 T's primary reliability risk is turbocharger wastegate actuator failure, with elevated incidence in high-mileage vehicles. Volvo TSB-01-05-03 documents this as a widespread issue, while timing belt neglect remains the leading cause of catastrophic engine failure. Extended service intervals and poor oil quality accelerate wear on the injection pump and turbo components, making adherence to the maintenance schedule critical.
Analysis derived from Volvo technical bulletins (2001-2005) and UK DVSA failure statistics (2010-2020). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-5204-T.
Comprehensive technical documentation and regulatory references
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VOLVO Official Site
Owner literature, service manuals, technical releases, and plant documentation.
EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
UK vehicle approval processes, import rules, and MoT guidance.
DVLA: Engine Changes & MoT
Official guidance on engine swaps and inspection implications.
Vehicle Certification Agency (VCA)
UK type-approval authority for automotive products.
Regulation (EC) No 715/2007
Euro emissions framework for vehicle type approval.
Commission Regulation (EU) 2017/1151
WLTP and RDE testing procedures for emissions certification.
GOV.UK: Vehicle Approval
UK compliance and certification requirements for imported and modified vehicles.
VCA Certification Portal
Type-approval guidance and documentation.
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