Volvo S60
Drive-E four-cylinder diesel with 2.0 litres and 110 kW for the D3 range. Common-rail injection with Euro 6 standard and single-stage turbocharging. Economical all-round diesel with good fuel consumption figures for high-mileage users on medium-length routes.
Sensible base engine
Perfectly adequate for everyday use. At the limit on the motorway, competent in city traffic.
Engine Weaknesses 7
The D3/D4 VEA diesel had a defective EGR cooler gasket that formed soot paste from condensation. EGR pipes and cooler clogged up to 90%. Volvo issued a recall in 2020 due to fire risk. Dealers reported 5–10 repairs per week.
Symptoms: Check engine light, engine throttling ('turtle mode'), EGR fault code, in severe cases smoke from engine bay
The D3 Drive-E uses a timing belt with a change interval of approx. 108,000 miles / 10 years. Many used vehicles have no documented belt replacement. Belt failure means total engine damage.
Symptoms: No warning before belt failure — engine stall. Belt check: look for cracking, wear, hardened rubber
The 2.0 D3 VEA requires sufficiently long drives for DPF regeneration. Short-trip use prevents complete regeneration cycles. DPF cleaning or replacement necessary at 150,000–200,000 km.
Symptoms: DPF warning light, power loss, increased fuel consumption, soot smell
The common-rail injectors of the VEA diesel show increasing wear from approximately 130,000–140,000 km. Leakage and return flow problems are typical. Replacement is costly, with parts around €500 each.
Symptoms: Rough running, hard cold starting, rattling at low RPM, excessive fuel consumption
The D3 Drive-E EGR valve carbons up from soot deposits, especially with short-trip use. According to forum reports, the fault occurs from as early as 15,000–20,000 km. EGR valve and cooler need occasional cleaning or replacement.
Symptoms: Check engine light, reduced power (limp mode), rough running especially at part throttle, increased consumption
Piezo injectors wear and lose precision. Leaking copper sealing rings cause hesitation. Fault code 'Injector offset learning at maximum limit' on multiple cylinders is typical.
Symptoms: Hesitation at idle and low load, fuel smell in cabin, noticeably higher consumption, black smoke
The D3's DPF clogs with predominantly short-trip use, as exhaust temperatures do not reach regeneration threshold. Costly cleaning or replacement required.
Symptoms: 'Soot filter full' message, reduced power, higher fuel consumption, occasional diesel smell in the cabin
Vehicle Weaknesses 9
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.
The electric tailgate on the V60 II shows malfunctions from 20,000–40,000 km, fails to close fully or responds with a delay. Known issue on SPA models from model year 2019 onwards.
The rain sensor, parking aid and adaptive lighting on early S60 III/V60 II show software faults. Creaks and clicks from the dashboard and door trims are also widespread.
Rear brake pads wear faster than the fronts on the S60 III and V60 II. Electric parking brake and automatic braking functions accelerate the wear further.
The interior trim on the S60 III (and V60 III) is considered insufficiently heat-stable. Temperature fluctuations create annoying clicks and creaks in the door trims, dashboard and seat area.
Software updates for the S60 III can resolve existing issues with the rain sensor, parking aid, power steering support or adaptive lighting, but sometimes introduce new faults. Volvo has not yet fully mastered the electronics.
MOT reports show above-average brake disc wear on the S60 III/V60 III. On plug-in hybrids in particular, rarely used brake discs corrode quickly due to predominant use of regenerative braking.
Reports & Tests
4 owner complaints filed with NHTSA (2018–2024). Most reported: Other (1), Electrical (1), Engine (1).