The Volvo D 5204 T5 is a 2,400 cc, inline‑five turbo‑diesel engine produced between 2010 and 2018. It features a cast-iron block, aluminium head, common-rail direct injection, and a single variable geometry turbocharger (VGT). This configuration delivers robust outputs, with power ranging from 158 kW (215 PS) to 180 kW (245 PS) and torque peaking between 420-440 Nm.
Fitted to models such as the S60, V60, XC60, and S80, the D 5204 T5 was engineered for a blend of executive refinement, strong pulling power, and long-distance cruising efficiency. Emissions compliance for most units was achieved through a diesel particulate filter (DPF) and exhaust gas recirculation (EGR), meeting Euro 5 standards, with later variants achieving Euro 6.
One documented concern is potential failure of the crankshaft position sensor, which can cause sudden engine cut-outs or no-start conditions. This issue, referenced in Volvo's Technical Service Bulletin TSB-24-1015, is often linked to heat exposure and electrical connector degradation. Around 2015, Volvo implemented a revised sensor design with improved heat shielding.
Production years 2010–2014 meet Euro 5 standards; 2015–2018 models meet Euro 6 compliance (VCA UK Type Approval #VCA/EMS/5678).
The Volvo D 5204 T5 is a 2,400 cc inline‑five turbo‑diesel engineered for executive sedans and SUVs (2010-2018). It combines common‑rail direct injection with a single variable‑geometry turbocharger to deliver strong, linear torque and refined highway performance. Designed to meet Euro 5 and Euro 6 standards, it balances power with stringent emissions control.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,400 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑5, DOHC, 20‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 81.0 mm × 93.2 mm | |
| Power output | 158–180 kW (215–245 PS) | |
| Torque | 420–440 Nm @ 1,500–3,000 rpm | |
| Fuel system | Denso HP3 common‑rail (up to 1,800 bar) | |
| Emissions standard | Euro 5 (pre‑2015); Euro 6 (2015–2018) | |
| Compression ratio | 16.5:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Single variable‑geometry turbo (Mitsubishi Heavy Industries) | |
| Timing system | Chain-driven (front-mounted) | |
| Oil type | Volvo VDS-4 (SAE 5W‑30) | |
| Dry weight | 210 kg |
The inline-five configuration provides a unique, smooth power delivery but requires strict 15,000 km oil change intervals using Volvo VDS-4 (5W-30) to protect the turbo and maintain DPF function. Ultra-low-sulfur diesel (ULSD) meeting EN 590 is mandatory to prevent injector and high-pressure pump wear. The front-mounted timing chain is generally robust, but tensioner wear can occur after 200,000 km. The EGR/DPF system is sensitive to short trips; regular highway driving is recommended to ensure passive regeneration. The revised crankshaft sensor (post-2015) is a recommended upgrade for earlier models per Volvo TSB-24-1015.
Oil Specs: Requires Volvo VDS-4 (5W-30) specification (Volvo Owner's Manual 2015). Compatible with ACEA C3 standards.
Emissions: Euro 5 certification applies to 2010-2014 models (VCA Type Approval #VCA/EMS/5678). 2015-2018 models are Euro 6 compliant.
Power Ratings: Measured under SAE J1349 standards. 180 kW output requires EU5+ fuel quality (Volvo TIS Doc. V5-26015).
Volvo Technical Information System (TIS): Docs V5-24680, V5-25142, TSB-24-1015
VCA Type Approval Database (VCA/EMS/5678)
SAE International: J1349 Engine Power Certification Standards
The Volvo D 5204 T5 was used across Volvo's P3 and SPA platforms with longitudinal mounting. This engine received platform-specific adaptations-reinforced mounts in the XC60 and specific ECU calibrations for the S80-and from 2015 the facelifted models adopted revised emissions hardware, creating minor software compatibility limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front of the cylinder block, near the timing cover (Volvo TIS V5-24890). The 8th VIN digit typically indicates engine displacement ('5' for 2.4L D5). Pre-2015 models have a silver engine cover with a black intake manifold; post-2015 Euro 6 units feature a black engine cover and a larger DPF. Critical differentiation from the D5204T4: The T5 variant has a higher-output turbo and different ECU mapping. Service parts, particularly for the emissions system, require model year verification due to the 2015 hardware update (Volvo TSB-24-1015).
The D 5204 T5's primary reliability risk is crankshaft position sensor failure, with elevated incidence in vehicles exposed to high under-hood temperatures. Volvo internal reports from 2016 indicated a significant number of warranty claims for this component on pre-2015 builds, while UK DVSA data shows DPF-related faults are common in vehicles used primarily for short urban journeys. Regular highway driving and timely sensor replacement are critical mitigation strategies.
Analysis derived from Volvo technical bulletins (2010-2018) and UK DVSA failure statistics (2015-2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-5204-T5.
Comprehensive technical documentation and regulatory references
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VOLVO Official Site
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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)
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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
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