Volvo S60
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.
Sensible base engine
Perfectly adequate for everyday use. At the limit on the motorway, competent in city traffic.
Engine Weaknesses 5
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.
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.
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.
EGR valve and EGR cooler become contaminated with soot particles and carbon deposits. A stuck valve causes power loss and elevated emissions. EGR cooler leakage can introduce water into the intake tract.
Symptoms: Power loss, rough idle, black smoke, P0400 fault codes, increased fuel consumption.
DPF clogs with frequent short-trip use as regeneration temperature is not reached. Interrupted regeneration cycles contaminate engine oil with diesel and raise the oil level.
Symptoms: DPF warning light, power loss, increased fuel consumption, engine oil smells of diesel, oil level rises.
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).