Volvo S60 1

Volvo's first five-cylinder turbodiesel with 2.4-litre common-rail injection. DOHC with 20 valves and Bosch EDC injection. Good torque delivery for comfortable cruising speeds; sensitive to fuel quality at high injection pressure.

• !! Injector seal leaking (Black Death) from 120,000 km

  The copper ring seal under the injectors fails to seal properly. Hot exhaust gas escapes, burning oil and forming black soot crusts around the injectors — known as Black Death.

  Symptoms: Black soot crusts visible around injectors, diesel/exhaust smell in engine bay, misfires, rough engine running.
  200–1,200 $
  Ad fuel injectorn-seal kit Volvo D5244TKupferdichtring D5 fuel injectorfuel injectorn-Klemme kit Volvo D5
• !! Timing belt + water pump from 160,000 km

  Replace timing belt every 160,000 km or 10 years. Water pump is belt-driven — if the old pump blocks after a belt change, the new belt is destroyed immediately. Always replace together.

  Symptoms: No warning signal. Missed service or old pump leads to engine damage.
  450–750 $
  Ad timing belt D5244Ttiming beltsatz Volvo D5 2.4Volvo water pump D5244T
• !! EGR valve sooted from 120,000 km

  EGR valve becomes clogged with soot particles and carbon deposits. When stuck closed power drops; when stuck open the engine runs rough and smokes.

  Symptoms: Power loss, rough idle, increased fuel consumption, black smoke, P0400 fault code.
  200–700 $
  Ad EGR valve D5244TEGR valve Volvo D5 2.4Volvo EGR cleaning

+ 1 more engine weaknesses + vehicle weaknesses

Upgraded D5 generation with 136 kW and increased injection pressure for improved torque of 450 Nm. Variable turbine geometry for improved response. Reliable with regular oil care; check the particulate filter on later versions.

• !! Injector seal leaking (Black Death) from 130,000 km

  The copper seal under the piezo injectors no longer seals properly. Combustion gases escape, burn the engine oil, and form black carbon crusts around the injectors — costly problem on the D5244T4.

  Symptoms: Black crusts around injectors, soot smell in engine bay, misfires, power loss, increased fuel consumption.
  300–1,500 $
  Ad fuel injector gasket D5244T4Volvo D5 185PS fuel injectorgasketfuel injectorn-Klemme kit XC90 D5
• !! Swirl flap linkage breaks from 150,000 km

  The plastic swirl flap linkage in the intake manifold fatigues and breaks. Loose parts can be sucked into the combustion chamber and damage valves or pistons. Damage up to €5,000 possible.

  Symptoms: Check engine light, power loss, rattling noise from intake area, in worst case engine damage.
  200–5,000 $
  Ad swirl flap linkage D5244T4Drallklappe Volvo D5 185PSintake manifold D5244T4
• !! Timing belt + water pump from 160,000 km

  Replace timing belt every 160,000 km or 10 years. Water pump must be changed at the same time without exception. New belt with old pump is a frequent cause of immediate consequential damage.

  Symptoms: No warning. Belt failure leads to total damage with bent valves.
  500–850 $
  Ad timing belt D5244T4timing beltsatz Volvo D5 185PSwater pump D5244T4

+ 2 more engine weaknesses + vehicle weaknesses

Five-cylinder turbocharged petrol engine with 180 hp. Solid engine from the modular range, sharing many parts with the 2.4/2.5L variants. Service the PCV system and timing belt regularly.

• !! Timing belt + CVVT camshaft adjuster from 120,000 km

  Interference engine — timing belt failure means total engine damage. Check CVVT unit during belt change; seals age and oil can enter the timing belt area, destroying the belt prematurely.

  Symptoms: No warning before belt breaks. CVVT fault: rattling noise on cold start, rough idle.
  500–900 $
  Ad Volvo B5204T5 timing beltsatzVolvo 2.0T timing beltsatzCVVT Volvo S60
• !! PCV hose cracks — oil on engine from 100,000 km

  The PCV hose from the engine block to the separator box develops cracks on the underside that are invisible from above. Result: oil accumulates on top of the engine and in the spark plug wells.

  Symptoms: Oil accumulation on top of engine, oil in spark plug tubes, whistling noise under load, slight oil consumption.
  80–250 $
  Ad Volvo PCV-set B5204Volvo crankcase ventilation SchlauchVolvo oil trap B5204T5
• !! ETM electronic throttle unit faulty from 130,000 km

  The electronic throttle module (ETM) wears out through internal contact corrosion and loose connectors. Mainly affects vehicles up to 2002. Volvo extended the warranty to 10 years. Rebuilt units available.

  Symptoms: Check engine light, reduced power, limp mode, engine stalls at idle, fluctuating idle speed.
  200–600 $
  Ad Volvo ETM repairVolvo throttle body elektronisch S60Volvo throttle module B5204T5

+ 1 more engine weaknesses + vehicle weaknesses

Naturally-aspirated five-cylinder with 2.4 litres from Volvo's proven modular engine family. DOHC with chain drive and from model year 2000 VVT on the intake camshaft. Robust and long-lived, typical of Volvo's earlier reliability philosophy.

• !! Timing belt replacement mandatory from 160,000 km

  Timing belt must be replaced every 160,000 km or 10 years — including water pump and tensioner. Neglect inevitably leads to valve damage and total engine failure.

  Symptoms: No warning before belt breaks. Vehicle suddenly fails to start or engine makes loud banging.
  450–750 $
  Ad Volvo timing beltsatz 2.4 B5244Stiming beltsatz B5244SVolvo water pump 2.4
• !! Camshaft adjuster migrates and fails to seal from 180,000 km

  The camshaft adjuster of the B5244S can migrate outward by up to 5 mm. The green O-ring slides over an edge and engine oil sprays between the timing sprocket and valve cover. Replacement part costs approximately €360.

  Symptoms: Oil loss at the timing side, oil mist in engine bay, check engine light for camshaft position
  400–900 $
  Ad camshaftnversteller B5244Scamshaft adjuster VVT Volvo 2.4camshaft phaser B5244Scamshaftnrad B5244S
• !! PCV oil separator clogged from 120,000 km

  The plastic PCV oil separator (oil trap) housing becomes brittle and clogs internally with sludge. Elevated crankcase pressure forces oil past seals, causing leaks.

  Symptoms: Rough idle, whistling noise from engine, oil mist from breather hoses, oil spots under the vehicle.
  150–500 $
  Ad Volvo PCV oil trap 2.4Volvo 8642955crankcase ventilation B5244S

+ 3 more engine weaknesses + vehicle weaknesses

Upgraded version of the five-cylinder naturally-aspirated engine with 125 kW and intake VVT. Same robust chain drive construction as the B5244S, but with more power from a revised intake system. Well suited to relaxed long-distance driving.

• !! Timing belt replacement mandatory from 160,000 km

  The timing belt also drives the water pump. Belt failure or skipping causes immediate engine damage. Replacement interval 160,000 km or 10 years including water pump.

  Symptoms: No warning before belt breaks. Sudden stall or loud rattling signals damage.
  450–750 $
  Ad timing beltsatz B5244S2Volvo timing beltsatz 2.4
• !! PCV oil separator clogged from 120,000 km

  The plastic PCV oil separator housing becomes brittle and clogs internally with sludge. Elevated crankcase pressure forces oil past seals — typical Volvo five-cylinder problem.

  Symptoms: Rough idle, whistling noise, oil mist from breather hoses, oil spots under the vehicle.
  150–500 $
  Ad Volvo PCV oil trap 2.4crankcase ventilation B5244S2
• !! Water pump and radiator susceptible at higher mileage from 150,000 km

  The B5244S2 naturally-aspirated engine shows cooling system weaknesses at high mileage: water pump and radiator can leak or fail. Water pump is part of the timing belt service kit; replace radiator immediately on any leak.

  Symptoms: Coolant loss, engine temperature rises in city traffic, slight streaking visible on radiator.
  300–900 $
  Ad water pump B5244S2radiator Volvo 2.4 S60 V70

+ 1 more engine weaknesses + vehicle weaknesses

First turbocharged engine in Volvo's five-cylinder family with low compression ratio and low-pressure turbocharger. Delivers consistent torque across a wide RPM band. Chain drive, solid construction with a well-known focus on longevity.

• !! ETM electronic throttle unit faulty from 100,000 km

  The Electronic Throttle Module (ETM) has a wearing carbon track in the position sensor. When it fails, the vehicle enters limp mode. Older engines are frequently affected.

  Symptoms: Engine runs rough, stalls when braking, idle surges, ETS warning light on, vehicle enters limp mode.
  200–600 $
  Ad Volvo ETM Electronic Throttle moduleVolvo throttle body B5244TETM repairsatz Volvo 8677867
• !! Timing belt + CVVT camshaft adjuster from 160,000 km

  Timing belt replacement every 160,000 km. The CVVT camshaft adjuster on the exhaust cam makes the job more complex. A rough adjuster or faulty solenoid causes camshaft faults P0340/P0365.

  Symptoms: Check engine light, hesitation under acceleration, hard starting, camshaft sensor fault after timing belt change.
  550–900 $
  Ad Volvo CVVT hub B5244TVolvo timing beltsatz B5244TCVVT solenoid valve Volvo 30650233
• !! PCV oil separator clogged from 100,000 km

  Plastic hoses and oil separator become brittle from heat and oil mist. Blockages create vacuum in the crankcase which draws oil out past camshaft and crankshaft seals.

  Symptoms: Whistling suction noise in engine bay, oil seeping at rear main seal, rising oil consumption, rear of engine oily.
  150–500 $
  Ad Volvo PCV oil trap B5244TVolvo oil separator-set 31338685crankcase breather Volvo 2.4T

+ 1 more engine weaknesses + vehicle weaknesses

Evolution of the B5244T with revised turbocharger and updated engine management for better power delivery. 147 kW with higher peak torque than its predecessor. Timing belt drive with CVVT adjuster; observe the 160,000 km replacement interval. Well suited to brisk motorway driving.

• !! ETM electronic throttle unit faulty from 100,000 km

  ETM carbon track wears out and causes failures. Known problem on older S60/V70 model years. Short trips in cold climates accelerate wear.

  Symptoms: Engine dies when stopping, rough idle, ETS warning light, limp mode under load.
  200–600 $
  Ad Volvo ETM B5244T3throttle body Volvo S60 T5
• !! Timing belt + CVVT adjuster from 160,000 km

  Replacement interval 160,000 km; check CVVT hub for roughness during service. An overdue timing belt and an old water pump are common causes of engine damage on these engines.

  Symptoms: No warning before belt breaks. Rough running after belt replacement points to CVVT fault.
  550–900 $
  Ad timing beltsatz B5244T3CVVT hub VolvoVolvo water pump 2.4T
• !! PCV oil separator clogged from 100,000 km

  Typical problem on all Volvo five-cylinders: plastic hoses become brittle, oil separator clogs. Crankcase vacuum draws oil past seals.

  Symptoms: Whistling noise, oil leak at rear crankshaft seal, rising oil consumption.
  150–500 $
  Ad PCV oil trap Volvo 2.4Toil separator-set Volvo 31338685

+ 3 more engine weaknesses + vehicle weaknesses

High-performance version of the turbocharged five-cylinder with VVT on both intake and exhaust camshafts and a stronger turbocharger. 191 kW for sporting performance with healthy long-term characteristics. Only fitted in the S60 T5 and V70 T5; sensitive to oil quality.

• !! ETM electronic throttle unit faulty from 100,000 km

  ETM position sensor wears out. Vehicle goes into limp mode. Problem particularly common on vehicles under 100,000 km dominated by short trips.

  Symptoms: Unstable idle, engine stalls at traffic lights, ETS light, no power in limp mode.
  200–600 $
  Ad ETM Volvo B5244T5throttle body T5 Volvo 2.4
• !! Timing belt + CVVT adjuster from 160,000 km

  Replace timing belt every 160,000 km or 10 years including water pump, tensioner, and idler pulley. Check CVVT hub for smooth operation to avoid camshaft errors after replacement.

  Symptoms: No warning. After replacement: camshaft sensor fault P0340/P0365 with defective CVVT hub.
  550–900 $
  Ad timing belt B5244T5CVVT hub Volvo 2.4Twater pump Volvo 2.4
• !! Piston rings stick due to PCV failure from 130,000 km

  The B5244T5 suffers from a vicious cycle: a faulty PCV oil separator increases crankcase pressure, which causes the compression rings to stick. Oil consumption then rises to 1 litre per 1,000 km or more.

  Symptoms: Severely elevated oil consumption, blue smoke under load, oil pressure warning light
  300–3,000 $
  Ad oil trap B5244T5oil separator PCV Volvo T5piston rings B5244T5PCV box Volvo S60 V70 T5

+ 3 more engine weaknesses + vehicle weaknesses

Turbocharged five-cylinder with 2.5 litres and 154 kW, manufactured in Skövde, Sweden. Mitsubishi turbocharger with intercooling for strong mid-range torque. Chain drive; popular as a harmonious all-round engine without extreme peaks.

• !! Timing belt + water pump mandatory from 160,000 km

  Replacement interval 160,000 km or 10 years. Timing belt drives water pump. An old pump failing after a belt change can instantly destroy the new belt.

  Symptoms: No warning signal. Missed service causes engine damage without warning.
  550–950 $
  Ad timing belt B5254T2water pump Volvo 2.5T
• !! PCV oil separator clogged from 100,000 km

  Plastic PCV system hoses become brittle and crack, separator clogs with sludge. Crankcase vacuum draws oil past camshaft and crankshaft seals.

  Symptoms: Whistling noise from under bonnet, oil spots on underbody at rear of engine, rising oil consumption, smoke from engine bay.
  150–500 $
  Ad PCV oil trap B5254T2Volvo 30650233flame trap 2.5T Volvo
• !! Turbo drain pipe seal leaking from 150,000 km

  The turbocharger oil drain line seals with O-rings that stretch at higher mileage. Oil loss at the turbo housing and increased oil consumption follow.

  Symptoms: Blue smoke after coasting, oil accumulation under the vehicle near the turbo, oil consumption 0.5–1 L per 1,000 km.
  300–1,000 $
  Ad Turbo-Ölrücklaufleitung gasket B5254T2Volvo turbo oil return Leitungturbocharger seal kit 2.5T

+ 1 more engine weaknesses + vehicle weaknesses

High-performance turbocharged five-cylinder with 221 kW specifically for Volvo's R models. High-pressure turbocharging for 221 kW and 400 Nm, only in combination with all-wheel drive. Maintenance-intensive; turbocharger and oil supply require particular attention on high-mileage vehicles.

• !! PCV oil separator critical on high-performance engine from 80,000 km

  The high-performance R engine generates more blow-by than standard engines. The PCV system must be absolutely tight. A clogged separator quickly leads to seal damage and oil loss.

  Symptoms: Oil mist from breather, heavy oil leak at rear of engine, elevated oil consumption by 5,000 km oil change interval.
  200–600 $
  Ad PCV-set Volvo S60Roil trap B5254T4 R-motor
• !! Turbocharger bearing wear from 150,000 km

  The heavily loaded turbocharger of the R engine shows premature bearing wear when oil changes are neglected or substandard oil is used. Cold starts without warm-up promote damage.

  Symptoms: Whistling or rattling turbo noise, power loss, blue smoke, oil visible in intercooler.
  800–2,500 $
  Ad turbocharger B5254T4 S60Rturbocharger Revisionssatz Volvo R
• !! Timing belt with water pump from 160,000 km

  Replacement interval 160,000 km. In the S60R/V70R this is especially important as total engine damage from a belt failure is even more costly given the high-performance specification. Include water pump replacement.

  Symptoms: No warning signal. Belt failure causes immediate engine damage from valve collision.
  600–1,000 $
  Ad timing belt B5254T4timing beltsatz Volvo S60R V70R

+ 1 more engine weaknesses + vehicle weaknesses