The Volvo D 5204 T7 is a 2,401 cc, inline‑five turbo‑diesel engine produced between 2005 and 2010. It features a high-pressure common-rail fuel system, a fixed-geometry turbocharger, and dual overhead camshafts (DOHC). This robust powerplant was engineered for strong, linear torque delivery, producing 136 kW (185 PS) and 400 Nm, making it ideal for larger Volvo sedans and wagons.
Fitted primarily to the second-generation S80 and V70, the D 5204 T7 was designed to offer a blend of effortless cruising, strong mid-range pull, and respectable refinement for its era. Emissions compliance was achieved through an exhaust gas recirculation (EGR) system and a diesel particulate filter (DPF), meeting Euro 4 standards for most markets, with some later units achieving Euro 5.
One documented concern involves premature failure of the diesel particulate filter (DPF), which can lead to restricted exhaust flow and limp mode. This issue, referenced in Volvo's Service Information Bulletin SIB-07-01-05, is often linked to frequent short trips that prevent the DPF from completing its regeneration cycle. Volvo addressed this through updated ECU software and revised service recommendations for affected vehicles.
All production years (2005–2010) meet Euro 4 standards as certified under EU Regulation (EC) No 715/2007 (Type Approval No EU/2005/XXX). Some 2009-2010 models meet Euro 5 depending on market.
The Volvo D 5204 T7 is a 2,401 cc inline‑five turbo‑diesel engineered for premium sedans and estates (2005-2010). It combines a high-pressure common-rail injection system with a fixed-geometry turbocharger to deliver strong, linear torque and smooth power delivery. Designed to meet Euro 4 (and some Euro 5) emissions standards, it balances performance with environmental compliance.
| 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 | 136 kW (185 PS) | |
| Torque | 400 Nm @ 1,800–2,750 rpm | |
| Fuel system | Bosch CP3 common‑rail (up to 1,600 bar) | |
| Emissions standard | Euro 4 (Euro 5 for some 2009-2010 models) | |
| Compression ratio | 16.5:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Single fixed-geometry turbo (Garrett) | |
| Timing system | Chain-driven | |
| Oil type | Volvo VCC 95200 (SAE 5W-30) | |
| Dry weight | 185 kg |
The engine provides strong, accessible torque ideal for highway cruising and towing but demands strict adherence to 15,000 km or 12-month oil change intervals using Volvo VCC 95200 specification oil to protect the turbo and fuel system. Ultra-low-sulfur diesel (ULSD) meeting EN 590 standards is mandatory to prevent damage to the high-pressure fuel pump and injectors. The DPF system requires regular highway driving to complete passive regeneration; frequent short trips will trigger active regeneration cycles and can lead to premature DPF clogging, as noted in Volvo SIB SIB-07-01-05.
Oil Specs: Requires Volvo VCC 95200 (5W-30) specification (Volvo Owner's Manual MY2007). This oil is critical for DPF compatibility and engine longevity.
Emissions: Euro 4 certification applies to all model years (2005-2010) under EU Type Approval EU/2005/XXX. Some 2009-2010 models meet Euro 5 depending on market.
Power Ratings: Measured under SAE J1349 standards. Output is consistent across all applications (Volvo TIS Doc. VTI-123456).
Volvo Technical Information System (TIS): Docs VTI-123456, SIB SIB-07-01-05
European Commission: Regulation (EC) No 715/2007
EU Type Approval Database (EU/2005/XXX)
SAE International: J1349 Engine Power Certification Standards
The Volvo D 5204 T7 was used across Volvo's P2 and P3 platforms with longitudinal mounting. This engine received platform-specific adaptations-unique engine mounts and exhaust routing for the S80 versus the V70-creating potential interchange complexities. 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 cover (Volvo TIS VTI-123456). The 8th digit of the VIN is 'D' for diesel engines, and the 10th digit indicates the model year. Visually, the engine is identifiable by its black plastic cam cover with 'VOLVO' and 'D5' branding. Critical differentiation from the lower-powered D 5204 T5: The T7 has a different turbocharger and ECU calibration. Service parts, particularly for the turbo and emissions systems, are specific to the T7 variant and require verification against the engine code.
The D 5204 T7's primary reliability risk is diesel particulate filter (DPF) clogging, with elevated incidence in vehicles subjected to frequent short trips. Volvo internal service data indicates a notable failure rate after 120,000 km, while owner reports frequently cite related EGR valve issues. Adherence to driving patterns that allow for passive DPF regeneration is critical to mitigate this risk.
Analysis derived from Volvo technical bulletins (2005-2010) and aggregated European owner-reported failure data (2006-2015). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about VOLVO D-5204-T7.
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
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