Volvo S60

The D4 190 hp VEA diesel was also affected by the 2020 EGR cooler recall. Clogged EGR systems with fire risk occurred on vehicles with the D4204T14 engine just as on the weaker D3. Check recall status.

Symptoms: Check engine light, engine throttling, in severe cases smoke from engine bay

The D4 Drive-E turbocharger shows turbine wheel damage from 80,000–120,000 km. Debris can contaminate the intercooler. Primary cause: frequent short trips and overdue oil changes.

Symptoms: Sudden power loss, black smoke, metallic whistling or grinding from engine bay, check engine light

On the D4 variant, the elevated EGR soot input also leads to accelerated DPF clogging. The combined EGR+DPF problem makes diagnosis difficult. A predominantly short-trip driving profile worsens both issues.

Symptoms: DPF warning light, engine power reduction, increased fuel consumption, occasionally rough running

The high-pressure common-rail injectors of the 190 hp D4 diesel are more susceptible to wear than those of the weaker D3, because the higher injection pressure places greater stress on precision components.

Symptoms: Rough engine running, hard starting, knocking at idle, fuel dripping at injector

The D4 Drive-E EGR cooler is prone to sludge build-up from overcooling. According to a Pistonheads forum thread, a Volvo service manager confirmed this as a known problem with this engine. Repair cost approx. 700 GBP.

Symptoms: Check engine light (EGR fault code), idle fluctuations, reduced fuel consumption after repair (from 50 to 38 mpg), occasional limp mode

DPF problems from short-trip use are common on the D4. Complete DPF regeneration requires extended motorway driving. Some vehicles need recall replacement of the particulate filter, intake tract and EGR.

Symptoms: DPF warning light, power reduction, elevated oil level from fuel entry during active regeneration attempts

Rubber hoses between the turbocharger and intercooler split over time, especially the hose on the turbine side. Typical problem commonly diagnosed first in forums. A DIY fix is possible.

Symptoms: Sudden power loss, hissing under load, check engine light P0299

Loose flange nuts on the rear toe link can abruptly worsen handling. Check for Volvo recall; affects S60 and V60 from September 2018.

MOT reports criticise above-average wear on tie rod ends, ball joints and suspension bushings at the front axle of the S60 III and V60 III. This occurs earlier with heavier engine variants or sporty driving.

On the S60 III and V60 III, the optional panoramic sunroof drainage channels block with leaves and dirt. Backed-up water enters the interior, often under the dashboard or onto the rear seat.