Volvo S60 (2010–2018)

What's good

Underfloor spare wheel conversion available at £475 inc VAT. Includes spare wheel jack socket wrench box and floor hatch.

What to watch out for

Powershift dual clutch automatic transmission requires fresh fluid every 3 years at a cost of £250.

4-3-2011: Volvo says, "Regarding the D2 diesel engine, the software has been improved so that particlefilter regeneration is facilitated. As for all modern diesel engines with particle filter, it is still recommended to do some driving at a bit higher loads once in a while, to ensure cleaning of the particle filter. However, our experience is that the D2 in V50 is really easy to regerarate, so it should work fine also for mostly city-driving. There is one second point concerning the D2: starting from late 2010 in V50, we do a hardware change from an additive particle filter to a catalyzed one. The additive filter type needed to be replaced or cleaned after 120,000 km, which is a costly repair. The new catalyzed solution does not require this, which is an advantage if the customer intends to keep the car for longer time."

29-12-2011: One report of total brake failure, braking from 25mph in traffic.

6-1-2012: 'Clunks' reported from the drivetrain of DRIVEe 1.6 D2, probably from the dual mass flywheel coping with the high gear ratios. Better not to run too low revs in any gear.

13-2-2013: Infotainment system prone to blowing fuses, which partially disables the car. Obviously if it keeps blowing fuses there is a fundamental fault.

29-8-2014: Reader quoted £3050 to replace DPF and injectors of 44k mile 2010 Volvo S60 1.6 D2 diesel, reduced to 50 per cent. Reader's typical journey is 25 miles. DMF had failed a few months previously, but within warranty.

12-2-2016: "Widespread" problem reported in Backroom with EGRs of new VEA D4 twin turbo diesel engine in all models of V40, S60, V60, XC60. 'Craig-pd130' explains: " Volvo chose the heavy-duty EGR route to achieving Euro 6 NOx emissions compliance, rather than AdBlue. So the VEA engine has a watercooled EGR cooler with serpentine passages inside. This seems to be inadequately designed, and quickly clogs up with sooty gunk from the exhaust gas (the tap-off for recycling is before the DPF) and the traces of oil that inevitably finds its way everywhere. It makes no difference whether owners use premium or supermarket diesel, or what mix of driving owners do (high motorway miles versus urban driving) - it affects all cars, usually within 6 to 9 months and 5,000 - 10,000 miles. In the majority of cases, this problem doesn't actually affect performance or driveability, it just throws a 'Check Engine' light. Only a fraction of owners have had their cars go into limp mode as a result of the problem." We think the problem is that this engine is optimaised to run on high cetane superdiesel and the problem is caused by attempting to run it on ordinary diesel.

13-7-2019: Long diatribe about Volvo 2.0 litre D4 VEA twin-turbo diesel engine in 2014 V60 at 47,000 miles (as above): "Given the current Safety Recall notification from Volvo about Inlet Manifolds melting and potentially causing engine fire. How are they getting away with not admitting the apparently unfixable fatal design flaw in the pre AdBlue D4 engine fitted to many models? The “advanced” watercooled EGR cooler with serpentine passages inside amounts to a self-destruct system for the engine. Massive numbers of posts on Volvo Forums from 2015 indicate the scale of the issue. Initially, EGR valves failed. Then, in 2016, a “permanent fix” with a new re-piped EGR cooler initially appeared to solve the problem but did not. It keeps the EGR clearer but lets it affect everything else: The black gunge is now deposited throughout the engine system and, according to a typical dealer from cases he has dealt with, causes massive problems up to and including replacement engines costing £8k. He correctly predicted the hesitation on my 47k mile 2014 V60 was due to the valve problem and £4,000 later, including a second replacement for a blocked manifold and new inlet valves (and the claimed permanent fix to the EGR cooler) he was proved right. Volvo initially refused to pay anything, but eventually paid 95% when I took photos and also copied them their own email to me from 2016 promising a permanent fix under the Volvo warranty. I threatened legal action if they didn’t pay up, but not all owners dare authorise repairs in advance of Volvo deciding to contribute, or otherwise. It is clear that payments made after strong protest are not “goodwill”, but an attempt to keep the lid on a potential multi-million pound issue. The dealer tells me Volvo’s internal official information confirms it is obvious that fires are caused by blocked manifolds. This only occurs in D4 engines with failed EGR systems. But the notification not only doesn’t mention the known cause, it doesn’t even state it affects D4 engines only, leaving owners to think it is a random new issue and not in fact the one Volvo might be in breach of contract over by failing to fix it under warranty. It would be safer if Volvo told owners of higher mileage D4s with original manifolds to be extra careful, but that would give the game away. Little wonder the DVLC Safety Recall system has been used, but there is no fix available so no Recall yet. The Volvo website is not clear whether Volvo will address the apparent impossibility of changing the nature of the EGR system or just try to stop cars catching fire.”

Recalls

October 2010: American recall over problem with side airbags of 2010 S60, S80, XC60 and XC70.

29-11-2010: American recall of 2011 Volvo S60, S80, XC60, and XC70. According to a bulletin from the National Highway Traffic Safety Administration, the problem is that "the software calibration for the fuel cut-off functionality in the engine control module (ECM) is too sensitive". As a result, the engines of affected vehicles could stall unnecessarily and suddenly, seriously increasing the risk of a crash.

03/12/2010 R/2010/224 VOLVO CAR C30, S40, V50, S60, V60, XC60, V70, XC70 & S80. Fire may occur. VIN 610264 to 613753

22/12/2010 R/2010/233 VOLVO CAR S40, V50 S60, XC60 Passenger seat may not be fitted correctly. VIN 488548 to 609751

22-7-2019: Volvo recalled 70,000 S60, S80, S90 saloons, V40, V60, V70, V90 estates and XC60 and XC90 models sold in the UK from 2014 to 2018 fitted with 2.0 litre diesel engines. (See carbycar V60 good/bad 12-2-2006 and 13-7-2019). Apparently the recall affects 500,000 Volvos worldwide. In a statement explaining why the recall was announced, Volvo said internal investigations “have identified that in very rare cases, the plastic engine intake manifold may melt and deform" causing a risk of fire. It also said that in “the most extreme cases” there is the possibility “that a localised engine bay fire may occur", though there have been no reports of injuties. Volvo will contact affected customers who will be asked to visit their local dealership for immediate work to fix the problem. Volvo has stated that the company will fix the faulty vehicles as quickly possible and that customers will not be charged for any costs related to the repair.

14-11-2019: Volvo has submitted to the DVSA its cure for the EGR Cooler issue with VEA diesel engines. These are: A redesigned EGR (Exhaust Gas Recirculation) coolant circuit to achieve engine working temperature faster; this will prevent excessive soot developing in the engine intake manifold system; New soot reducing software; Cleaning of temperature/pressure sensors. Volvo emphasises that there have only been a small number of reports of intake manifold failure, a subset of which have led to engine bay fires. Volvo is confident that the corrective action offers a robust solution.

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