Which XC90 D5 and the Core Plug issue?
 

Hi All

I'm looking to purchase a 04 / 05 XC90, but am concerned as to what I may be letting myself in for!

I've read up on all the usual issues, angle gear and splines, engine mounts, core plug, intercooler etc, but I cant find a definitive guide as to which engine will be the least problematic.

A friend purchased an XC90 163 with a documented history last week which decided to pop its core plug on the way home as well as gunking up its intercooler with oil and road debris. The bill was rather horrific!

So, the 163 seems a good choice for short runs (which it will be used mainly for) as there is no DPF, but the core plug does scare me somewhat as I cant seem to find a car for sale via a used car dealer which has had this replaced previously (the GDPR has really messed up obtaining service invoice history).

Does anyone know if the 163 Euro IV has the revised core plug, or knows exactly which engine number upwards doesn't have this problem?

Also, what sort of cost would I be expecting to pay a garage to replace the plug, and are there any other seals that will need to be done whilst its in pieces? I've found an XC90 that had the spline shaft replaced 11 years ago / 70K miles with the uprated one, so I assume this will still be fine?

Thanks everyone!

my core plug failed at 190k on a euro3 d5 paid 300 for repair but mine is 2wd v70 the plug is a 3£ part . do the crankshaft oil seal aswell its abt 18£

Thanks Simmy, was that an engine out job as well on the V70?

The 163 Euro 4 has a DPF and swirl flaps.

The 163 Euro 3 has neither.

That said, the 163 Euro 4 was never available in the XC90

There are a few issues that are specific to the earlier 163 BHP E3 D5 engine - the crankcase core plug, the starter ring gear, but all considered I think most would agree it is - on balance - the easiest to maintain, most reliable, most refined and lowest running costs of all the D5 engines.

FYI I think your friend has been mis-advised, the core plug failure causes an oil leak into the bellhousing to the gearbox - it does not affect the intercooler.

Also GDPR shouldn't have any impact on you obtaining service history as it's not data from which you are able to uniquely identify an individual...

The 163 BHP E4 D5 did not have the core plug problem but came with other issues and was never fitted to UK XC90's as has been said...

The core plug is expensive to fix as you have to remove the engine or gearbox to get the necessary access (it's actually easier to remove the engine on the XC90) but it certainly doesn't affect every XC90. I would say we see far more people on here with gearbox or intercooler issues.

Thanks guys, being s newbie it's really helpful.

Re the 163 Euro IV not being available in the UK, having looked on the DVLA site, and also data checks the 55 plate 163 has a slightly different CO2 emission figure and a cheaper road tax.


Can anyone elaborate as to why this may be please?

Hi, yes that 163 will be Euro3 .


around the same period the E4 185bhp engine was introduced and the Road Tax on these rose significantly in early 2006.


It is possible to get an E4 185 pre tax hike but it will also be pre facelift :regular_smile:

The E4 185 bhp came with a better 6 speed Geartronic box rather than the earlier 5 speed Geartronic or a 6 speed manual ( quite rare ).

Manual gearbox models are also cheaper to tax than Geartronic.

Thanks S60D5-185. Would it be safe to say that the later 163 is a detuned 185 without the DPF and other emission control features, and doesn't suffer the core plug issue?

Yes - but that engine was never fitted to XC90s, it was used in V70/S60 etc.

Ah, okay but what did Volvo do to the 163 to make the emissions lower?