Volvo S60
Entry diesel with 2.0 litres and 133 kW in the high-output version (D4/D5), alternatively 88 kW (D2) for maximum efficiency. Same common-rail platform as the other Drive-E diesels. Suitable for mixed urban and cross-country use.
Compact diesel everyday engine
130 kW D4 in the compact models: adequate and efficient. Not a sports car, but a good commuter.
Engine Weaknesses 4
The VEA diesel D4204T5 uses timing belt drive. Replacement interval 105,000 km or 10 years. The serpentine belt must be maintained separately: if it breaks, it can wrap around the timing belt and cause total engine damage.
Symptoms: No warning before belt breaks. Loud clattering or sudden stall indicates damage.
Even the weakest VEA diesel D2 (D4204T5) is affected by the EGR cooler problem. With this engine's already low exhaust temperatures, EGR soot paste formation is particularly common.
Symptoms: Check engine light, engine throttling, increased fuel consumption, rough idle
The 120 hp D2 with its lower load uptake has particular difficulty completing DPF regeneration on short trips. Regular motorway runs are mandatory. At minimum every 2,000 km a run of over 30 minutes at motorway speeds.
Symptoms: DPF light early after purchase, power reduction, soot smell when stopping
The 1,800-bar piezo injectors of the D4204T5 can leak at mileages over 150,000 km. Leaking injectors cause oil dilution by diesel and rough running. Diagnose via return flow rate measurement.
Symptoms: Rough idle, increased fuel consumption, diesel smell in engine oil, slight soot smell.
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).