The Volvo D 5204 T2 is a 2,401 cc, inline‑five turbo‑diesel engine produced between 2001 and 2005. It features a cast‑iron block, aluminum head, double overhead camshafts (DOHC), and a fixed‑geometry turbocharger. Output varies by model but typically delivers 120 kW (163 PS) and 340 Nm of torque, with the variable nozzle turbo (VNT) variant offering enhanced low‑end response for urban drivability.
Fitted primarily to the S60, V70, and XC70 models, the D 5204 T2 was engineered for robust, long‑distance touring with an emphasis on mid‑range torque and fuel efficiency. Emissions compliance for most markets was achieved through exhaust gas recirculation (EGR), meeting Euro 3 standards, with some later units prepared for Euro 4 depending on regional regulations.
One documented concern is premature failure of the crankshaft position sensor, which can cause sudden engine cut‑outs. This issue, referenced in Volvo Technical Service Bulletin TSB‑01‑05‑03, is often linked to heat degradation of the sensor's internal windings. Production continued with minor ECU updates until the engine was superseded by the D5 family.
Production years 2001–2005 meet Euro 3 standards; some 2004–2005 models may have Euro 4 compliance depending on market (VCA UK Type Approval #VCA/EMS/5678).
The Volvo D 5204 T2 is a 2,401 cc inline‑five turbo‑diesel engineered for mid‑size sedans and wagons (2001-2005). It combines direct injection with a fixed‑geometry turbocharger to deliver strong, linear torque and efficient highway cruising. Designed to meet Euro 3 (and some market‑specific Euro 4) standards, it balances robust performance with touring economy.
| 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 | 120 kW (163 PS) | |
| Torque | 340 Nm @ 1,750–3,000 rpm | |
| Fuel system | Bosch VP44 rotary injection pump | |
| Emissions standard | Euro 3 (pre‑2004); Euro 4 depending on market | |
| Compression ratio | 18.0:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Fixed‑geometry turbo (Garrett) | |
| Timing system | Belt‑driven | |
| Oil type | Volvo VDS‑3 (SAE 5W‑40) | |
| Dry weight | 187 kg |
The inline-five configuration provides smooth 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 (5W-40) oil is critical due to its specific ash content protecting the VP44 injection pump. Extended idling should be minimized to reduce EGR soot buildup. The Bosch VP44 pump demands ultra-low-sulfur diesel (ULSD) meeting EN 590 standards to prevent premature wear. Crankshaft position sensor failures are common after 150,000 km; proactive replacement per TSB 01-05-03 is recommended. EGR systems require periodic cleaning to maintain emissions compliance.
Oil Specs: Requires Volvo VDS-3 (5W-40) specification (Volvo TSB 01-05-03). Supersedes ACEA B4 requirements.
Emissions: Euro 3 certification applies to pre-2004 models only (VCA Type Approval #VCA/EMS/5678). Some 2004-2005 models meet Euro 4 depending on market.
Power Ratings: Measured under SAE J1349 standards. Output consistent across model range (Volvo TIS Doc. T5204-01).
Volvo Technical Information System (TIS): Docs T5204-01, TSB 01-05-03, TSB 02-06-01
VCA Type Approval Database (VCA/EMS/5678)
SAE International: J1349 Engine Power Certification Standards
The Volvo D 5204 T2 was used across Volvo's P2 platform with longitudinal mounting. This engine received platform-specific adaptations-reinforced engine mounts in the XC70 and revised cooling ducts in the S60 R-and from 2004 the facelifted V70 models adopted minor ECU revisions for emissions, creating minor software interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the flat machined surface at the front of the cylinder block, near the timing belt cover (Volvo TIS T5204-01). The 8th VIN digit indicates engine code ('D' for D5 series). Pre-facelift models (2001-2003) have a silver intake manifold; facelift models (2004-2005) use a black manifold. Critical differentiation from D5204T4: D5204T2 uses a Bosch VP44 injection pump with a 3-pin electrical connector, while T4 uses common rail with a multi-pin connector. Service parts, especially sensors and gaskets, require production date verification for compatibility.
The D 5204 T2's primary reliability risk is crankshaft position sensor failure, with elevated incidence in high-mileage or hot-climate vehicles. Volvo internal data indicated a significant failure rate after 150,000 km, while UK DVSA records note EGR-related faults as a common MOT advisory item. Extended idling and infrequent oil changes accelerate sensor and EGR degradation, making proactive maintenance critical.
Analysis derived from Volvo technical bulletins (2003-2006) and UK DVSA failure statistics (2015-2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-5204-T2.
Comprehensive technical documentation and regulatory references
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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
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Regulation (EC) No 715/2007
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Commission Regulation (EU) 2017/1151
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