Volvo XC60
Evolved 3.2-litre naturally-aspirated engine with reduced internal friction and 179 kW. Improved crankshaft bearing and revised thermal management. Manufactured at the Ford plant in Wales; check chain tensioner above 150,000 km.
Naturally aspirated SUV
3.2-litre naturally aspirated engine in the XC60: refined and without turbo fuss. Not a racer, but a solid companion.
Engine Weaknesses 4
B6324S5 camshaft end plugs can leak oil — same TSB issue as the predecessor. Volvo has issued a repair procedure (TNN21-28).
Symptoms: Oil seeping from the side of the cylinder head, oil smell after driving, gradual oil loss.
The B6324S5 uses a diaphragm for PCV regulation. When the diaphragm fails, full intake vacuum acts on the crankcase: oil is actively drawn into the intake tract. A functioning PCV system shows slight negative pressure at idle.
Symptoms: Oil consumption with no visible leaks, oil in air filter element, rough idle, whistling noise.
Even the revised B6324S5 shows slight to moderate oil consumption at higher mileages. Up to 0.5 L per 1,000 km is internally tolerated by Volvo, but should be monitored.
Symptoms: Oil level visibly drops between oil changes, no smoke or leaks detectable.
The six-cylinder in the XC90 regularly needs new engine mounts from about 120,000 km. Thermostat and coolant circuit are under greater load in this heavy SUV. Check thermostat proactively at coolant changes.
Symptoms: Vibrations at idle and under load, engine rocking, temperature rise in city traffic.
Vehicle Weaknesses 10
D5 diesel (2009–2013) is prone to frequent cylinder head cracks and worn cylinder liners. Coolant loss without a visible leak is the warning sign; total engine failure is possible.
A recall was issued for five-cylinder diesel XC60 I vehicles because the ribbed belt can break prematurely. Without this belt, the alternator, power steering pump and A/C compressor all fail; in the worst case the engine overheats.
The Haldex pump on the XC60 I AWD blocks up with oil sludge when the oil change is neglected. Recommendation: change Haldex oil every 30,000 km, otherwise the rear axle loses drive. Pump replacement costs €400–800.
Foam insulation and wheel arch liners trap moisture and dirt; rust forms from the inside behind the clips. Check wing and wheel arch at the 10 o'clock and 2 o'clock positions.
Volvo itself confirms: on the XC60 I the two-component windscreen adhesive at the upper edge detaches. Water gets under the carpet, damages electronics and leads to mould growth. Documented multiple times in online forums.
The XC60 I draws an elevated quiescent current through its numerous control units. Many owners report battery failures after 2–3 years, especially with predominantly short-trip use. Deep discharge can damage electronics.
MOT reports and used car advisers confirm: the front axle on the XC60 I is frequently flagged. Tie rod ends and ball joints wear early, especially in combination with the heavy diesel engine.
The electric tailgate on the XC60 I stops opening due to software faults or fails to close fully. Gas struts fail after 40,000–70,000 km, causing the tailgate to drop uncontrolled.
MOT reports regularly flag the XC60 I for wear on tie rod ends, control arm joints and suspension bushings. Springs and dampers fail more frequently from the third MOT onwards.
The BLIS blind spot sensor on the XC60 I fails through moisture ingress in the wiring loom. Seat heaters fail frequently on older vehicles. Both issues are typical but not safety-critical.
Reports & Tests
314 owner complaints filed with NHTSA (2008–2017). Most reported: Other (65), Wipers & Visibility (62), Electrical (54).