Recalls: Volvo Mk.2 S60
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 Mk.2 S60
2010-11 model year Volvo S60: airbag may not deploy
In October 2010, a recall was issued for model year 2010 and 2011 Volvo S60 models in the VIN range 000194 to 000701. 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 S60: fuel cut-off may activate
In November 2010, a recall was issued for model year 2011 Volvo S60 vehicles fitted with a six cylinder petrol engine and in the VIN range 000194 to 012895. For these vehicles, the software calibration for fuel cut-off functionality in the engine control module (ECM) and the transmission control module (TCM) is too sensitive. As a result, the 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 model year Volvo S60: excessive seat travel
In December 2010, a recall was issued for model year 2009 to 2011 Volvo S60 vehicles in the VIN range 000390 to 014817. 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).
2011 model year Volvo S60: potential fuel leak
In May 2011, a recall was issued for 2011 model year Volvo S60 vehicles fitted with a 2.0-litre turbocharged petrol engine and in the VIN range 031679 to 033476. 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 S60: potential fuel seepage
In May 2011, a recall was issued for model year 2011 Volvo S60 vehicles fitted with either a 2.0-litre turbocharged or a 3.2-litre normally aspirated petrol engine and in the VIN range 032029 to 032502. 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).
2012 Volvo S60: airbags may not deploy
In March 2012, a recall was issued for 2012 Volvo S60 vehicles in the VIN range 076075 to 170045. 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).
2011 model year Volvo S60 2.4 Diesel: loss of drive and steering assistance
In November 2013, a recall was issued for 2011 model year Volvo S60 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 000194 to 015058 (PRA 2013/13877).
2011-15 model year Volvo S60 T4: coolant leak
In November 2016, a recall was issued for 2011 to 2015 model year Volvo S60 vehicles that had 1.6-litre turbocharged petrol engines. During engine warm-up and under certain driving and climate conditions – such as high acceleration or high engine load immediately after cold start, particularly in cold climates – there may be a small leakage of coolant fluid. If this occurred, a warning message would appear in the instrument display. At worst, the coolant leakage could result in an oil seepage that caused a smell or smoke. If the oil seepage reached a hot surface, a fire could develop in the engine bay. The recalled Volvo S60 vehicles had serial numbers in the range 001139 to 369491, and were available for sale from 1 August 2011 to 7 November 2016 (PRA 2016/15729).
2017 model year Volvo S60: airbags may not inflate completely
In January 2017, a recall was issued for 2017 model year Volvo S60 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).
2015-16 model year Volvo S60: potential fuel leak
In January 2019, recall campaign R29904 was issued for 2015-16 model year Volvo S60 vehicles. Due to cracks in the inner layer of the fuel hose and the pressurised fuel system, the fuel hose could leak. The driver may notice the fuel leak as a result of a fuel odour. The fuel leak, however, posed a hazard to other road users and the fuel could ignite in the presence of an ignition source. To fix, the hose on the fuel line was to be replaced. For the VINs of the recalled vehicles, please see PRA 2018/17249.
2014-18 model year Volvo S60: intake manifold could melt or deform
In July 2019, recall campaign R29939 was issued for 2014-18 model year Volvo S60 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.
2013-18 Volvo S60 Diesel: engine intake manifold could melt or deform
In January 2020, recall campaigns R29947 and R29948 were issued for Volvo S60 vehicles that were available for sale in Australia from 1 May 2013 to 31 May 2018 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.2 S60: front seatbelt fasteners
In August 2020, recall campaign R10029 was issued for Volvo Mk.2 S60 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.
2013-18 Volvo Mk.2 S60 Diesel (4 cyl): overheating and fire hazard
In August 2020, recall campaigns R10025 and R10026 were issued for Volvo Mk.2 S60 vehicles that had four-cylinder diesel engines and were available for sale from 1 August 2013 to 1 December 2018. 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.
2013-18 Volvo Mk.2 S60 Diesel (4cyl): overheating and fire hazard #2
In September 2020, recall campaign R10027 was issued for Volvo Mk.2 S60 vehicles that had four-cylinder diesel engines and were available for sale in Australia from 1 August 2013 to 1 December 2018. 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.2 S60
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.
2010-11 Volvo S60 T6: excessive oil consumption, white exhaust smoke and low/uneven idle
In April 2012, Volvo issued Technical Journal 24643 for Volvo S60 T6 vehicles that had SI6 turbo 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.
2010-12 Volvo S60: rear suspension noise or pulling across the road
In November 2012, Volvo Cars North America issued Technical Journal (TJ) 25336 for 2010-12 Volvo S60 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.
2010-12 Volvo S60 T5: harsh 5-4 downshift and/or rough engagement at standstill
In May 2012, Volvo issued Technical Journal TJ 25994 for Volvo S60 T5 vehicles that were manufactured from November 2010 to January 2012 (serial numbers in the range 0017819 to 0128042). According to the Technical Journal, the driver may experience a harsh shift or jerk when the automatic transmission (AW TF80SC) shift from fifth to fourth gear when coasting; the driver may also feel a rough or jerky engagement when the vehicle is stationary and the driver is releasing the brake to accelerate again.
To fix, the transmission control module (TCM) was to be re-programmed. If, however, the chassis number was between 086037 and 119529 (original TCM hardware part number 30751946 or 31342781), then the TCM was also to be replaced (with part number 31312609) and the TCM re-loaded. The vehicle was then to be driven as per the adaptation instructions.
2010-11 Volvo S60 with petrol I5 engine: oil pressure sensor
In 2013, Volvo UK issued a ‘non-code action’ for Volvo S60 vehicles that had five-cylinder petrol engines and were manufactured from 22 June 2010 to 14 May 2011. For these Volvo S60 vehicles, a software issue during production meant that the oil pressure sensor was not activated. As a result, no warning message would appear in the Driver Information Module (DIM) if the oil pressure in the engine was too low. To rectify, a software download was to be performed to activate the sensors. The affected Volvo S60 vehicles had serial numbers in the range 001148 to 146365 (NCA/2013/019).
2015 model year Volvo S60 T5: oil leakage from VVT pulley
In October 2016, Volvo issued Technical Journal TJ 29131.5.0 for 2015 model year Volvo S60 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 S60 T5: excessive oil consumption
In April 2016, Volvo issued Technical Journal TJ-31216 for 2015-16 model year Volvo S60 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.
2015 Volvo S60 with stop/start and automatic transmissions: engine may not restart
In 2015, Volvo UK issued a ‘non-code action’ for 2015 Volvo S60 vehicles that had:
- Four-cylinder engines with stop/start functionality;
- Automatic transmissions; and,
- VINs in the range YV1622FS3C2039001 to YV126MFK2G1398852 (Torslanda production); or,
- VINS in the range YV1FS41L0G2390004 to YV1FS41L1G2398920 (Ghent production).
For affected Volvo S60 vehicles, a starter motor fuse could fail due to becoming overloaded and this could prevent the engine from restarting after it had shut down as part of its stop/start operation. For these vehicles, the starter motor fuse was to be replaced by an upgraded fuse (NCA/2015/019). It is understood that these vehicles were manufactured from 8 April 2015 to 19 August 2015.
