Volvo XC60 (2008 – 2017) Review

Intermittent fault with electronic/electric parking brake release eventually traced to a duff driver's door sensor that was not allowing the brake to be released because it thought the door was open.

2010 TSB related to rising sump oil levels in D5 Diesel engines with a DPF which is caused by excess fuel entering the engine sump via cylinders during DPF regeneration cycles. The solution is to reprogram the engine management software to reduce the volume of fuel used during the regeneration cycle and drain the excess oil back to midway between the min/max levels on the dip stick, then keep an eye on it. Really, any engine that has had its lube oil contaminated by diesel needs a lube oil change.

Report of new 'serpentine' aux belt fitted to 50k mile 2011 Volvo XC60 came off within 50 metres of leaving repair garage and wrapped itself around lower timing belt pulleys, potentially wrecking the engine. Apparently there had been a factory official adjustment of the aux belt tensioner at 54k miles.

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 particlefilter, it is still recommended to do some driving at a bit higher loads once in awhile, to ensure cleaning of the particle filter. However, our experience is thatthe D2 in V50 is really easy to regerarate, so it should work fine also for mostlycity-driving. There is one second point concerning the D2: starting from late 2010 in V50, we do ahardware change from an additive particle filter to a catalyzed one. The additivefilter type needed to be replaced or cleaned after 120,000 km, which is a costlyrepair. The new catalyzed solution does not require this, which is an advantage ifthe customer intends to keep the car for longer time."

Timing belt tensioner of 2.5 litre Volvo engine can fail in as little as 50,000 miles, flinging off the belt and wrecking the engine, then landing the owner with a £6,000 bill.

One report so far (27-3-2010) of failed vanes on the turbo of a D5.

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

Complaint of Geartronic bands slipping on 19k mile 2010 XC60 D5.

Complaint of rear brake discs and pads of 2012 Volvo XC60 D5 auto needing replacing at 34,260 miles.

Complaint of tailgate lock failure on 50k mile 2011 Volvo CX60 that had been serviced independently.

Satnav hardware failed on 2007 XC60. Quoted £1,000 to repair.

Reader report that windscreen of 45k mile 2010 Volvo XC60 de-bonded, leading to a loss of structural integrity and a water leak into the cabin onto electrical components. Apparently common: http://volvoforums.com/forum/volvo-xc60-51/leaking-front-windshield-2010-xc60-67995/

"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."

GB Autos has encountered a fault in a control module under the left front passenger floor of some V70, XC70. V60, XC60. XC90, causing multiple faults if the headlamp flash is actuated. Replacement electronic control modules are in stock in advance of customer problems.

Complaint of Geartronic transmission of 58k mile 2011 XC60 2.4 D5 AWD jerking and not changing down smoothly when decelerating for a roundabout or junction. Diagnostics found no fault.

There were three past DVSA recalls concerning the alternator/PAS pump belt and tensioner on earlier XC60 engines. The original part was prone to failure and, under the recalls, a replacement belt and tensioner assembly were fitted as necessary. f an XC60 missed this it is prone to the belt failing, but the original type of belt is not available so the whole assembly has to be changed.

Sequence of problems with Volvo XC60 D5 Geartronic now at 41,000 miles: Car taken to dealer with message ABS/DSTC service required. The ABS red warning light illuminated as did the Dynamic Stability and Traction Control light. Dealer could only detect a possible abs sensor issue. Judged safe to drive. Message cleared but reappeared soon after then subsequently cleared itself for 6 weeks. It then re-appeared. ABS light almost constantly illuminated, and after moving slightly forwards there is a series of clunks where the car no longer wishes to accelerate smoothly the DSTC caption illuminates and a only a restart allows the car can be driven. It has also thrown up an engine service required (message, no warning light) which went away after a couple of restarts (the previous day the car had had 2 hours at high speed on the motorway so it should not be a particulate filter issue). Now it has a constant City safety Service Required but the menu system would indicate this selected on. Then, having driven it down a hill it wanted to rev at 3000 rpm when it came to a stop and was not keen on accelerating away. A restart got it going. Subsequently, the gear box is not locking up in the higher gears. When driving at 70 mph foot taken off the accelerater, the engine goes back to idle. All this has started with the hot weather which may be a coincidence.

Report of gas struts starting to fail on hatchback of 2012 Volvo XC60, making a groaning noise. Volvo dealer wants £500 to replace them. Apparently available on the Internet from £12 each to £46 each.

Report of driver's door lock of 2013 Volvo XC60 failing while car was under warranty, then subsequently passenger door lock failing and owner being charged for the repair after which a rear door lock also failed and owner was charged for the repair.

Problems reported with 2014 Volvo XC60 2.0 diesel bought from a car supermarket in August 2016. In February 2017 engine management light came on and local Volvo dealer replaced EGR cooler and hose under warranty. In September 2017, light came on again. Volvo dealer cleaned the O2 sensor (no charge) and mentioned a "flap" was sooted up and they would refer to Volvo to see if they would cover this as the EGR fix was known to cause further problems (heard nothing). In December 2017, light came on again and owner told will have to pay £500 (discounted from £800) for a new exhaust manifold as current one sooted up and a further clean of O2 sensor. Suspect that this has been caused by repeated short runs from cold.

Report of unpleasant jerk/clonk from drivetrain of 2011 Volvo XC60 2.4 AWD at 55,000 miles when charging from reverse to drive and it's getting worse. Volvo dealer seemed to fix it last year but the problem is back. Local garage thought an oil change to the Haldex unit might fix it but it hasn't. Likely to be due to a disparity of more than 3mm between the tyres.

Warning message reported on 35k mile 2013 Volvo XC60 About 3 weeks ago a warning message saying "gear selector service required" came up on the dash. After £90 of diagnostics dealer called owner to say that it needed a new gear selector module and almost 3 hours labour. Cost £518.70 (including the diagnostic check).

2013 Volvo XC60 2.4 D4 R Design required a new automatic gear selector at 35k miles costing £518.

Report of tailgate strut failure every 4 years on a Volvo XC60, costing £800 for replacements every time.

Report that within a few days of the latest service of a 60,000 mile 2014 Volvo XC60 D4, a dashboard message appeared "reduced engine performance" above which was a cute symbol of a tortoise. Independent specialist diagnosed a possible EGR valve issue, a known problem.

Report of recently purchased 54,000 mile Volvo XC60 D4 Drive-E 181 having had a new EGR and now needing a new EGR cooler and associated pipework "at enormous cost". We think the reason for D4 EGR failures is attempting to run them on ordinary diesel when the finely tuned injectors of the D4 engine are "optimised" to run on Superdiesel. See S60 2010 12-2-2016. Though an EGR can be replaced wityhout also replacing the cooler it is common for the cooler to leak soon after reassemlt so advisable to replace the cooler at the same time. The job usually costs around £1,500.

Report of recently purchased 110,000 mile 2014 Volvo XC40 D4 repeatedly going into restricted performance mode, probably because the owner is tryi9ng to run it on ordinary deasel when the injection system absolutely requires superdiesel.

Report of "rough changes into first gear" of 8-speed torque converter automatic transmission of 2016 Volvo XC90 2.0 litre 2WD. Volvo dealer has reset the gearbox but its still the same.

Report of EGR failure on 2016 Volvo XC60 D4 at 70,000 miles. Engine light came on soon after fuel hose recall work was carried out. Reason might be trying to run a D4 on ordinary diesel rather than the super it is optimised for. Happily Volvo dealer took it on the chin and replaced EGR and coiler FoC.

Report of significant water ingress to 2011 Volvo XC60, now starting to affect the electrics. Soaked driver's floormat over a long period of time; water drippoing from ceiling light cluster.

Report of 'coolant low' light coming on in 2014 Volvo XC60 at 135k miles the day after a Volvo service. Owner topped it up, but it came on again a few miles later. Owner took it to a different Volvo dealer 4 days after the service to be told the head gasket has failed and it needs a new eengine costing £11,200. (Unable to establish when last timing belt, tensioner, waterpump and aux belt replacement had been carried out, or if the servicing dealer left the cap off or loose on the expansion tank.)

Report that 2014 Volvo XC60 D4 at 70k miles needed new intake swirl flaps, new EGR cooler (under goodwill), plus new EGR (50% goodwill) and, because it was using 0.6 litres of oil in 1,400 miles, might need a new engine. No indication given of which diesel fuel had been used.

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.”

Report of problems with EGR of 2014 Volvo XC60 D4 2.0 litre bought 3 months previously. First repair dealer replaced the EGR but not the cooler. After a long trip went into limp mode. EGR cooler cleaned out as was blocked solid. Now runs more smoothly but spluttery on start-up after being left for a few days.

Report of Aisin Geartronic automatic transmission of 67,000 mile 2014 Volvo XC60 D4 AWD 2.4 litre 5-cylinder going into limp home mode showing "transmission service required " while towing a caravan. Went into a Volvo dealer and as part of the repair needed a new TCM module. Horton Cars explains what can go wrong here.

Report of 2015 Volvo XC60 requiring new rear brake discs at 40,000 miles.

Report of intermittent electrical problems with no warning on a 2011 Volvo XC60. "Power steering goes, handbrake shows a fault, DSTC shows a fault and Park Assist. Car drove well for a year since garage had it for 1 week to sort this out and could find no fault. Now all these problems have returned." (Since purchase in March 2018 has also needed new alternator, EGR valve, battery and fuel tank sender pum. Garage have downloaded a 2019 software fix but within 24 hrs all problems returned.

Report of alternator failure in 2014 Volvo XC60 D4 Automatic SE at 64,000 miles. See 5-1-2017 about problem with alternator drivebelts.

Report of engine management light of 2014 Volvo XC60 D4 VEA coming on in August 2019. Car is driven 9,000 miles a year, some short urban journeys, but at least 60 miles a week at motorway speeds. Because the light is one of the indicators in the pre-recall letter of a risk of engine fire, owner booked it in at his dealer. Was told if it wasn't the recall issue he would be charged £100 for diagnostics. Later received a call telling him that the engine needed a major top end rebuild involving replacing the cylinders, valves and injectors due to them being “sooted up” but not to worry as Volvo would carry 100% of the costs as “goodwill”. The work took a week. Thread on Volvo Owners Club Forum dating back to 2015 with 2300+ posts covers the issue of carbon build up in these engines. (Also covered in V60 carbycar entry) It seems that the EGR is re-introducing soot to the engine that then builds up into carbon in the combustion chambers.

Report of the central information screen on Volvo XC60 (2016) flashing on and off. Dealer says the system needs a software update at a cost of £154.80.