Recalls: Volvo Mk.1 XC60
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Volvo XC60
2008-09 model year Volvo XC60: cooling fan may stop
In June 2009, a recall was issued for model year 2008 and 2009 Volvo XC60 vehicles in the VIN range 000362 to 002634. For these vehicles, the engine cooling fan may permanently stop working due to a software error in the Fan Control Module (FCM). If the fan stopped, it may caused reduced air conditioning performance and the driver will be informed of the increased coolant temperature by a yellow information lamp in the Driver Information Module (DIM) with the ‘reduce speed’ text message. If the engine temperature continued to rise, the red warning lamp would illuminate with text instructions to stop the car safely (PRA 2009/10870).
Volvo XC60 T6: fuel pump malfunction
In September 2009, a recall was issued for Volvo XC60 models fitted with the T6 engine and in the VIN range 0000214 to 0062308. For these vehicles, fuel Pump Electronic Module (PEM) may not operate as intended and inhibit the start of the fuel pump – this could cause the engine not to start, start roughly and/or run roughly at idle. Furthermore, the engine may also stop shortly after start-up which may cause stalling (PRA 2009/11056).
2009-10 model year Volvo XC60: fuel line rail could come loose
In December 2009, a recall was issued for model year 2009 to 2010 Volvo XC60 vehicles in the VIN range 0027474 to 0070444. In these vehicles, the fuel line rail cover – which protected fuel lines underneath the car – may not have been properly attached. In this situation, the fuel line rail cover may come loose and expose the fuel lines underneath the vehicle to damage (PRA 2009/11288).
2009 model year Volvo XC60 D5: premature belt tensioner wear
In June 2010, a recall was issued for 2009 model year Volvo XC60 vehicles fitted with a D5 diesel engine and in the VIN range 000001 to 028507. In these vehicles, the belt tensioner may experience premature wear. In this situation, the driver may hear greater noise from the engine bay; at worst, there could be a loss of drive, power steering assistance and immobility of the vehicle (PRA 2010/11694).
2009-10 model year Volvo XC60: loss of power steering assistance
In March 2010, a recall was issued for model year 2009 and 2010 Volvo XC60 vehicles in the VIN range of 000001 to 086575. In these vehicles, the steering gear high pressure lines joint connecting to the steering gear may not have been properly assembled. If so, the driver may notice oil leakage. At worst, due to the high pressure in the system and the specific engine installation, oil may be sprayed onto hot surfaces and produce smoke or the ignition of oil, potentially causing a fire in the engine bay. Furthermore, the substantial oil leakage may cause a sudden loss of power steering assistance (PRA 2010/11478).
2011 model year Volvo XC60 Diesel: loss of engine coolant
In July 2010, a recall was issued for 2011 model year Volvo XC60 vehicles fitted with a 2.4-litre diesel engine and in the VIN range 135123 to 137267. In these vehicles, the spring band clamp mounted on the radiator hose connection to the water inlet pipe spigot may not sufficiently secure the hose, potentially leading to the hose coming loose during driving and resulting in a loss of engine coolant water. The driver will be informed of this concern through a warning symbol and text message ‘low coolant level stop safely’ in the instrument panel. If ignored, however, this condition will lead to engine damage (PRA 2010/11823).
2010-11 model year Volvo XC60: airbags may not deploy
In October 2010, a recall was issued for model year 2010 and 2011 Volvo XC60 models in the VIN range 087281 to 141518. For these vehicles, there may be an electrical short circuit in the driver’s airbag clockspring wiring connector. If the deviation occurred, the supplement restraint system (SRS) light would be constantly lit and the message ‘airbag system service required’ would be displayed in the Driver Information Module (DIM). If the driver ignores the warning, the airbag may not deploy as intended – or at all – in the event of a collision (PRA 2010/12059).
2011 model year Volvo XC60: fuel cut-off malfunction
In November 2010, a recall was issued for model year 2011 Volvo XC60 vehicles fitted with a six cylinder petrol engine and in the VIN range 135074 to 165252. For these vehicles, the software calibration for fuel cut-off functionality in the engine control module (ECM) and the transmission control module (TCM) was too sensitive. As a result, engine idle speed may drop during city driving and cause the engine to suddenly stop. While the driver would be able to restart the vehicle, the driver would need to depress the accelerator pedal further than normal to drive the vehicle. The driver may also find the gear engagement harsh and the transmission operation noisy (PRA 2010/12144).
2009-11 Volvo XC60: curtain airbags may not deploy as intended
In November 2010, a recall was issued for model year 2009 to 2011 Volvo XC60 vehicles in the VIN range 003297 to 138358. For these vehicles, the inflatable curtain airbags may not have been correctly assembled, such that they may not deploy as intended in the event of a collision (PRA 2010/12145).
2009-11 model year Volvo XC60: front seat stop lugs
In December 2010, a recall was issued for model year 2009 to 2011 Volvo XC60 vehicles in the VIN range 021301 to 167764. For these vehicles, the front power seat stop lugs may not be assembled to specification. As a result, the maximum allowable seat travel may be exceeded and positioning of the seat beyond the intended maximum could increase the risk of injury to the front passengers in the event of a collision (PRA 2010/12230).
2009-11 model year Volvo XC60 Diesel: engine failure
In January 2011, a recall was issued for 2009 and 2010 model year Volvo XC60 vehicles fitted with a five cylinder diesel engine and in the VIN range 050022 to 127444. For these vehicles, the engine oil level may exceed the maximum level marking, leading to increased engine speed. At worst, the engine may not stop running when it is switched off and may continue to run until the engine breaks down (PRA 2011/12256).
2011 model year Volvo XC60: washer fluid level sender
In April 2011, a recall was issued for 2011 model year Volvo XC60 vehicles fitted with a headlight cleaning system and in the VIN range 084237 to 179792. For these vehicles, the headlight cleaning pump may affect the washer fluid level sensor. As such, the driver may not receive information on the instrument panel when the washer fluid level is low, constituting non-compliance with the Motor Vehicle Standards Act 1989, ECE R45 (PRA 2011/12502).
2011 model year Volvo XC60: potential fuel leak
In May 2011, a recall was issued for 2011 model year Volvo XC60 vehicles fitted with a 2.0-litre turbocharged petrol engine and in the VIN range 192616 to 195006. For these vehicles, the fuel supply line may have been incorrectly manufactured, leading to a fuel leakage and the driver detecting a fuel smell. At worst, a fuel line connection may completely detach and the engine may stall due to a lack of fuel (PRA 2011/12544).
2011 model year Volvo XC60: potential fuel seepage
In May 2011, a recall was issued for model year 2011 Volvo XC60 vehicles fitted with either a 2.0-litre turbocharged or a 3.2-litre normally aspirated petrol engine and in the VIN range 193110 to 193764. In these vehicles, the connectors for the fuel pressure line and the purge line may have been switched during production. As a result, the pressure line may be missing an O-ring which could result in fuel seepage in sub-zero temperatures and the customer noticing a fuel smell (PRA 2011/12545).
2009-10 model year Volvo XC60: premature belt tensioner wear
In October 2011, a recall was issued for 2009 and 2010 model year Volvo XC60 vehicles fitted with the 2.4-litre diesel engine and in the VIN range 028508 to 127483. In these vehicles, the auxiliary belt tensioner may experience premature wear, leading to excessive noise, a loss of power-steering assistance and immobilisation of the vehicle (PRA 2011/12871).
2011 model year Volvo XC60 Diesel: premature belt tensioner wear
In November 2013, a recall was issued for 2011 model year Volvo XC60 vehicles that were fitted with 2.4-litre turbo-diesel engines. In these vehicles, premature wear on the auxiliary belt tensioner could lead to noisy operation and, at worst, a loss of drive and power steering assistance. The affected vehicles had serial numbers (i.e. the last six digits of the VIN) in the range 135123 to 168101 (PRA 2013/13877).
2012 model year Volvo XC60: airbags may not deploy
In March 2012, a recall was issued for 2012 model year Volvo XC60 vehicles in the VIN range 237068 to 271560. In these vehicles, the wiring harness under the driver and/or passenger seat may not have been properly affixed to the seat frame during vehicle assembly. As a result, the harness connector could detach from the socket and the airbags may not function as intended, causing the SRS warning lamp to illuminate or the airbags to fail to deploy during a crash (PRA 2012/13055).
2016 model year Volvo XC60: starter motor fuse may blow
In September 2015, a recall was issued for 2016 model year Volvo XC60 vehicles that had four-cylinder petrol engines and automatic transmissions. In these vehicles, the fuse for the starter motor may blow in a stop/start sequence; if this occurred, it would not be possible to restart the vehicle. The recalled Volvo XC60 vehicles had serial numbers (i.e. the last six digits of the VIN) in the range 775015 to 814753 (PRA 2015/14907).
2016 model year Volvo XC60: engine cuts out
In March 2016, a recall was issued for ‘2016 model year’ Volvo XC60 vehicles that had serial numbers (i.e. the last six digits of the VIN) in the range 775048 to 905018. In these vehicles, the engine may momentarily cut-out and then immediately restart – this could cause disturbance in some electrical systems such as shut down of the instrument cluster, infotainment system and loss of power steering assistance. The sudden loss of power and reduced power steering assistance could pose a hazard to the driver and other road users (PRA 2016/15242).
2017 model year Volvo XC60: airbags may not inflate completely
In January 2017, a recall was issued for 2017 model year Volvo XC60 vehicles. In the event of a collision, the airbag igniter may not cause adequate inflation of the driver, passenger and/or seat airbags in these vehicles. If the airbags did not inflate completely, the risk of injury for the driver and other occupants would be increased (PRA 2017/15822).
2015 model year Volvo XC60 with five-cylinder diesel engine: inaccurate fuel gauge
In February 2017, a recall was issued for ‘2015 model year’ Volvo XC60 vehicles that had five-cylinder diesel engines. In these vehicles, the fuel gauge may show that there is fuel in the vehicle even when the fuel tank is empty. If the vehicle were to run out of fuel while it was being driven, the loss of power would increase the risk of a collision with other road users. It is understood that the recalled Volvo XC60 vehicles had serial numbers in the range 701003 to 763403 (PRA 2017/15928).
2014-17 model year Volvo XC60: intake manifold could melt or deform
In July 2019, recall campaign R29939 was issued for 2014-17 model year Volvo XC60 vehicles. In these vehicles, the engine valve may leak and cause the engine intake manifold to melt or deform. If the engine intake manifold were to melt or deform, the vehicle may enter ‘limp home’ which restricted engine power and speed; it also posed a fire hazard. This reduction in engine power and fire hazard increased the risk of a collision and injury. For the VINs of the recalled vehicles, please see PRA 2019/17676.
2013-17 Volvo XC60 Diesel: engine intake manifold could melt or deform
In January 2020, recall campaigns R29947 and R29948 were issued for Volvo XC60 vehicles that were available for sale in Australia from 1 May 2013 and which had four-cylinder D4204T14 or D4204T5 diesel engines. In these vehicles, an engine valve may leak and cause the engine intake manifold to melt or deform. If this occurred, there may be unusual engine operation, activation of the engine malfunction indication light, engine interruption or lack of power, or the possibility of a localised engine bay fire – these posed a risk of injury to vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2019/18031 and PRA 2019/18032.
Volvo Mk.1 XC60: front seatbelt fasteners
In August 2020, recall campaign R10029 was issued for Volvo Mk.1 XC60 vehicles. In these vehicles, the flexible steel cable that was connected to the outboard side of the front seatbelts may fatigue and separate from the seatbelt. If this occurred, the occupant would not be properly restrained and this increased the risk of injury or death in the event of a collision. For this recall, replacement parts were not expected to be available until after October 2020 and owners were to be advised – in writing – of how to secure the front seatbelt while waiting for those parts to arrive. When the parts became available, the seatbelt fasteners were to be replaced. For the VINs of the recalled vehicles, please see PRA 2020/18415.
2013-17 Volvo Mk.1 XC60 Diesel (4 cyl): overheating and fire hazard
In August 2020, recall campaigns R10025 and R10026 were issued for Volvo XC60 vehicles that had four-cylinder diesel engines and were available for sale after 1 August 2013. If the cooling system had to be refilled, air could become trapped in the cooling system and this might result in insufficient cooling of the engine components – this could cause damage to engine components and a fire in the engine bay. A fire would pose a risk of injury and death to vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2020/18433 and PRA 2020/18450.
2013-17 Volvo Mk.1 XC60 Diesel (4cyl): overheating and fire hazard #2
In September 2020, recall campaign R10027 was issued for Volvo XC60 vehicles that had four-cylinder diesel engines and were available for sale in Australia from 1 August 2013. If the cooling system in these vehicles had to be refilled, air could become trapped within the cooling system and this could result in insufficient cooling of engine components. Insufficient cooling could, in turn, damage engine components and cause a fire in the engine bay – these circumstances increased the risk of a collision and injury to vehicle occupants and other road users. For the VINs of the recalled vehicles, please see PRA 2020/18560.
Problems and faults: Volvo Mk.1 XC60
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
2009-11 Volvo XC60 3.2 and T6: excessive oil consumption, white exhaust smoke and low/uneven idle
In April 2012, Volvo issued Technical Journal 24643 for Volvo XC60 3.2 and T6 vehicles that had engines manufactured prior to 4 May 2011. According to the Technical Journal, these vehicles may exhibit the following symptoms:
- Low oil level;
- Excessive oil consumption;
- Poor idle quality;
- White smoke from the exhaust;
- An oil smell; and/or
- Illumination of the yellow warning symbol and ‘Low oil level’ or ‘Oil level low’ messages in the Driver information Module (SIM).
To determine if the vehicle had an oil consumption condition,
- The engine should be inspected for external leakage on and around the engine, especially around the cylinder head/cam cover/timing cover area. If an external leakage was present, then the following steps were not applicable;
- An oil consumption test could be performed if there was no prior record of low oil levels and oil being added between service intervals;
- The spark plugs were to be examined for evidence of previous oil over-filling since this could be the cause of DTCs related to oil consumption (specifically DTC P030000 and/or P030600). As the Technical Journal acknowledged, these engines were susceptible to over-filling since it was difficult to easily check the oil level with the dipstick;
- A cylinder leakage test was to be performed to determine if oil consumption was coming from an area other than the cam cover;
- If the cylinder leakage tests were OK and if the spark plug from cylinder #6 had more soot than the others, this suggested that the cam cover was not properly sealed from the factory. If so, the cam cover was to be removed so that the sealing surface could be inspected. If the sealing surface was discoloured by oil, it was most likely that there was a leak between the cam cover and the cylinder head in the area facing the positive crankcase ventilation (PCV) channel which connected the breather box and the PCV gallery. To fix, the cam cover was to be re-sealed. The cam cover seal was improved at engine production date 15 April 2010 (15041000001); and,
- If the cylinder leakage tests were OK and there was a spark plug from a cylinder other than #6 which had more soot than the others, then the valve guides were to be inspected. Valve guide leakage was most commonly found when there was excessive white smoke from the exhaust and had been observed on engines with build dates before 4 May 2011 (040511B01272). Each valve guide was to be tested by removing the cam cover, removing the valve tappets, plugging all but one intake port and plugging all intake ports, injector ports and the PCV inlet. Air pressure could then be applied to one intake port at a time and, by using automatic transmission fluid (ATF) for colour differentiation, ripples or bubbles in the ATF would indicate a leak that required the cylinder head to be replaced.
Please note that the testing procedure described above differs for models that have B6324S4 PZEV (‘Engine 94’) or B6324S2 PZEV (‘Engine 96’) engines – these may require new pistons and oil control rings. For information on those engines, please refer to Technical Journal 24643.
2009-12 Volvo XC60: rear suspension noise or pulling across the road
In November 2012, Volvo Cars North America issued Technical Journal (TJ) 25336 for 2009-12 Volvo XC60 vehicles. According to TJ 25336, the front bushing in the rear longitudinal stay could fail due to corrosion of the bushing’s outer metal ring and this would cause the vulcanised rubber to loosen. If this occurred, the vehicle may exhibit the following symptoms:
- A knocking or clunking noise from the rear suspension when driving on uneven roads;
- The vehicle pulling or drifting across the road (to the right or left) due to rear wheel camber being out of specification; or,
- Unstable rear suspension on curvy roads.
To fix vehicles with these symptoms, the bushing was to be replaced; after installation of the bushing, rust-proofing wax was to be sprayed on the outer metal ring of the bushing. To prevent this problem from occurring in future vehicles, waxed bushings which were less susceptible to corrosion were introduced in production from mid-March 2012.
2015 model year Volvo XC60 T5: oil leakage from VVT pulley
In October 2016, Volvo issued Technical Journal TJ 29131.5.0 for 2015 model year Volvo XC60 T5 vehicles with B4204T11, T12 or T9 engines. In these vehicles, the driver may receive a low oil level warning in the Driver Information Module (DIM) and/or notice oil leakage from the engine. According to the Technical Journal, these symptoms may be due crack in the plug from the Variable Valve Timing (VVT) pulley. To fix, the two plugs in both of the VVT pulleys were to be replaced.
2015-16 model year Volvo XC60 T5: excessive oil consumption
In April 2016, Volvo issued Technical Journal TJ-31216 for 2015-16 model year Volvo XC60 T5 vehicles with the B4204T11 or B4204T12 engines. According to the Technical Journal, these vehicles may experience high oil consumption – this may be indicated by the driver receiving the ‘low oil level’ message in the Driver Information Module (DIM). To fix, new pistons and piston rings were to be fitted – this required the cylinder head and balance shafts to be removed. The part number for the piston kit was 31493184.
From engine serial number 1501327, engines were fitted with these revised pistons and piston rings from the factory.
