Volvo XC60

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

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.

Mass recall in 2020 for around 750,000 vehicles worldwide due to faulty automatic emergency braking (AEB). Check recall status at the Volvo dealer and have the software update applied.

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.

The optional air suspension on the XC60 II frequently fails in cold weather. The compressor and dryer must be replaced together (Stage 3 repair); replacing just the compressor rarely lasts more than 2–3 months.