Volvo S60
Ford four-cylinder turbodiesel with 1.6 litres marketed as the Volvo DRIVe version. SOHC with timing belt and Euro 5 standard. Very economical; conceived for high-mileage drivers with an efficiency focus.
Sensible, no sport pretence
D2 in the S60: low running costs, modest driving fun. Want the D4 or T5? That's where the fun is.
Engine Weaknesses 4
The original 240,000 km (150,000-mile) replacement interval of the PSA-derived DV6 was reduced to 140,000 km (87,500 miles) in 2014. Older vehicles maintained on the original interval carry elevated risk.
Symptoms: Sudden engine failure without warning, engine damage on belt snap
The D4162T engine block can crack during overheating events (e.g. from untreated coolant loss). Reports of cracked blocks following coolant starvation are documented in English-language Volvo forums.
Symptoms: Coolant loss following overheating, engine noises, white smoke, engine oil in coolant
The DPF of the PSA DV6/D4162T requires motorway runs for regeneration. With predominantly urban use the filter clogs quickly. An interrupted regeneration cycle (e.g. from engine stall) accelerates clogging.
Symptoms: DPF warning light early after purchase, power reduction, increased fuel consumption, soot smell when parking
On the PSA-derived DV6 diesel, the injector copper seals at the cylinder head interface tend to leak. Cylinder 3 is statistically the most commonly affected; exhaust residues seep out along the outside of the injector.
Symptoms: Soot deposits on outside of injectors, rough running, poor cold-start behaviour
Vehicle Weaknesses 10
The five-cylinder diesel D5 is prone to cylinder head cracks and worn cylinder liners, particularly on models built between 2010 and 2013. Coolant loss without a visible leak is the first warning sign.
A software fault can cause the electric parking brake on models up to 2014 to release unintentionally. A Volvo recall and software update fix the problem.
A faulty weld between the rotor shaft and the hydraulic brake assembly was found on the V90 II and S90 II. If it fails, ABS, ESC and brake assist are disabled. Volvo issued a recall in 2021.
On XC60 II vehicles built between September 2018 and April 2019, nuts and bolts at the rear axle may be too loose. Handling can change abruptly; check recall status.
Water gets into the windscreen wiper motor and causes it to fail. SPA platform models are affected; a 2020 recall addressed incorrectly tightened wiper arms. Visibility in rain significantly impaired.
At higher mileages, worn tie rod ends, ball joints and suspension bushings on the S60 II/V60 I are frequently flagged by MOT inspectors. Tyre wear is very sensitive on this vehicle.
The audio and navigation system in the S60 II/V60 I fails due to cold solder joints on the control unit board — a known issue across this Volvo model generation. Replacement units cost over €700.
The Sensus infotainment system on the SPA platform (XC60 II, S90 II, V90 II, S60 III, V60 II) freezes or reboots while driving. Software updates improve stability. Steering wheel controls drop out sporadically.
The optional panoramic roof on the V90 II and S90 II shows malfunctions when opening/closing automatically. Faulty sensors or motor controllers can be expensive; water ingress possible if the seal is damaged.
The BLIS blind spot sensor on the S60 II/V60 I reacts to moisture ingress in the wiring harness with false alarms or complete system failure. Recalibration or sensor replacement is required.
Reports & Tests
333 owner complaints filed with NHTSA (2010–2018). Most reported: Engine (138), Other (50), Electrical (41).