XC90 2 litre D5 rear engine oil leaks - cracked blocks

[OriginalTDave]

So my XC90 was showing an oil leak between engine and gearbox with oil very slowly dripping from the bottom of the bell housing. Eventually time was made after lockdown for a main dealer investigation. Gearbox out and the problem was found to be a crack in the main engine block above the rear main bearing which goes through the oil gallery..hence the oil leak.
The good news is it was covered by warranty ( just) as it was right at the end of the 3 year period.. A replacement short motor has been fitted and associated hardware needed in the engine change over, but interestingly enough the oil pump plus main belts are not changed. It is not in the volvo list of items to replace.

Now the bad news.. this is a known issue!. Volvo issued an internal bulletin about the problem last year with pictures to show where the crack goes. This fault is with all the 2 litre diesels ( not sure about petrol models) across the new model ranges.. my XC90 is not a one off !.
So before your warranty expires check your bell housing for any slight oil weep at the bottom of it, if its black oil its engine oil.. You will have to remove the lower engine tray to view this.

[Roosterb]

Worrying. And another reason not to own one of these vehicles without a comprehensive warranty.

[DriverDen]

Originally Posted by OriginalTDave

check your bell housing for any slight oil weep at the bottom of it, if its black oil its engine oil.. You will have to remove the lower engine tray to view this.

Is it possible to get some pictures of where to look for the less mechanical minded?

[mr rusty]

I suggest that this sort of design fault can be pursued beyond the end of the warranty because it was both known about and must have been present at the time of purchase - so 6 years would be the limit.

[Philip Fisher]

Originally Posted by mr rusty

I suggest that this sort of design fault can be pursued beyond the end of the warranty because it was both known about and must have been present at the time of purchase - so 6 years would be the limit.

It can be challenged beyond 3 years yes, but you will have a fight and nothing is guaranteed. Far better to find before 3 years is up.....

[OriginalTDave]

Originally Posted by DriverDen

Is it possible to get some pictures of where to look for the less mechanical minded?

The dealers have the photos in their bulletin, but its internal to Volvo and they wont release them to owners ( yet).. I have seen these so I know it exists.
In truth the only way to see the block crack ( if you have one) is to remove the gearbox and flywheel. The crack travels across the alloy block above the rear main bearing, they appear to be hairline cracks, but once it goes into the oil gallery the oil leak starts.
So as long as your car does not have any oil leaking from its bell housing, then you should be ok, at least in theory.
I am surprised Volvo has not come clean over this, as this issue is known and across models and dealers are seeing the fault, be it in smallish numbers.

[LukasDitt]

Originally Posted by OriginalTDave

The dealers have the photos in their bulletin, but its internal to Volvo and they wont release them to owners ( yet).. I have seen these so I know it exists.
In truth the only way to see the block crack ( if you have one) is to remove the gearbox and flywheel. The crack travels across the alloy block above the rear main bearing, they appear to be hairline cracks, but once it goes into the oil gallery the oil leak starts.
So as long as your car does not have any oil leaking from its bell housing, then you should be ok, at least in theory.
I am surprised Volvo has not come clean over this, as this issue is known and across models and dealers are seeing the fault, be it in smallish numbers.

Hi Dave,

recently I have found your "story" about XC90 with oil leak and cracked engine block. I am from Czech republic and a friend of mine had some weeks ago the same problem. He has XC90 D5 2016, mileage 120 000 km. But there is one "small" difference - in Volvo service they told him, that this is "normal wear" and asked him for 10 000 euros for the repair.

Could you please tell me more details about your story? Or even better, where you found out, that this is for Volvo well known problem? If you want, I can send you some pictures about our case.

Thanks a lot, Lukas