Popular Swedish mid-size SUV known for safety and comfort. The D4 diesel engine is part of Volvo's Drive-E family, emphasizing fuel efficiency and power balance. Main concerns center on the EGR system and DPF, especially on cars driven mainly for short trips. The 2014-2017 models are subject to a major inlet manifold fire recall affecting 70,000 UK vehicles. Power steering issues, oil consumption (early models), and transmission problems (especially Powershift) need checking. Best years: 2016-2017. Avoid: 2010 (fuel pump issues), 2015 (engine problems). D4 engines use timing belts, not chains.
Water-cooled EGR system clogs with soot, especially on short-trip cars · more· less
The D4 engine uses a water-cooled exhaust gas recirculation (EGR) system that becomes clogged with soot over time, triggering the engine check light. This is especially common on Euro 6 diesels used primarily for short trips. Multiple owners report going through "countless EGR valves." Volvo has issued recalls for EGR-related issues. Symptoms include check engine light (though performance may be unaffected initially), reduced power, and increased fuel consumption. Parts cost €200-400 (aftermarket) or €500-1,000+ (genuine Volvo). Labor adds €300-500 depending on dealer vs independent shop. Some owners opt for EGR deletion via software (€180), though this isn't dealer-friendly.
DPF clogging & regeneration failure€800 - €2,500
Diesel particulate filter blocks on urban-driven cars, requires long drives or replacement · more· less
Frequent short trips prevent proper DPF regeneration, causing the filter to clog with soot. Symptoms: decreased performance, increased fuel consumption, rising engine temperature, increased black smoke. The DPF masks oil consumption - you won't see blue smoke even if the engine burns oil. Solution 1: Take a long motorway drive (30+ minutes at 100+ km/h) to force regeneration. Solution 2: Check DPF sensor - may be faulty (€150-300). Solution 3: Replace entire DPF unit. Parts cost €200-700 depending on brand. Labor is 4-6 hours (€400-800). Total: €800-2,500 at dealer. Independent garages charge less. Volvo has issued DPF recalls.
Inlet manifold fire risk (2014-2017 recall)€0 (recall) - €2,000
Plastic inlet manifold can melt and cause engine fire - major recall affects 500,000 cars worldwide · more· less
Volvo recalled half a million cars worldwide (70,000 in UK alone) after discovering that plastic inlet manifold may melt and distort, potentially causing engine fire. Carbon deposits build up causing inlet manifold flaps to seize. Recirculated exhaust gases cannot pass efficiently and build up heat. Affects all 2014-2017 XC60s with 2.0L diesel. Symptoms: unusual smells in cabin, engine warning light, hesitation under acceleration, lack of power, overheating. CRITICAL: If you notice any of these, stop immediately. Verify with VIN whether recall work completed before purchase. Repair should be free under recall. If recall not done and manifold fails, replacement costs €800-2,000.
Power steering failure€500 - €2,600
High-pressure line joint fails, causing fluid leak and sudden loss of power assist · more· less
The joint between the power steering high-pressure line and steering gear may not be assembled correctly on some XC60s, leading to fluid leaking and sudden loss of powered assistance. Symptoms: whining noises, difficulty turning, sudden loss of power assist. Repair cost depends on component: Power steering pump €890-1,000, Control module €485-540, Control valve €230-280, Rack and pinion €2,300-2,600. Most common is the high-pressure line issue which costs €500-800 to repair. Note: Later SPA platform XC60s use electric power steering (no fluid), so this mainly affects first-generation models. Have the steering system inspected during pre-purchase check.
Turbocharger failure€2,000 - €3,300
Twin-turbo D4 engines prone to turbo oil return pipe sludge and bearing wear · more· less
The D4204T14 engine uses twin turbochargers known for oil return pipe sludge buildup in stop-start urban driving. Expected lifespan: 150,000-200,000 km if well-maintained. Symptoms: loss of power, black smoke, whistling noises, oil leaks around turbo. Parts cost €800-1,100 for aftermarket, €1,200+ for OEM. Labor: 3-7 hours (some mechanics drop the engine for access as turbos are tight to bulkhead). Total cost: €2,000-3,300 at independent shop, higher at dealer. Some remanufactured units have upgraded oil return pipes. Prevention: Regular oil changes (every 10,000 km or annually), let engine idle 30 seconds before shutting off after motorway driving. This is a specialist job - not DIY-friendly.
Aisin TF-80SC 6-speed auto suffers valve body issues; Powershift dual-clutch has high failure rate · more· less
Manual gearboxes are reliable. Automatics have issues. Aisin TF-80SC (6-speed): Symptoms include harsh shifting, hesitation, slipping, grinding noises, fluid leaks, especially in stop-and-go traffic. 90% of cases: valve body failure. Software update helps ~90% of owners (free at dealer). Valve body replacement: €1,500-2,500. Full transmission replacement: €5,500-7,300. Powershift (Getrag/Ford dual-clutch on T5 models): Even worse - clutch failure, ECU solder joint issues, faulty sensors. Ford paid €10 million fine in Australia over Powershift problems. Clutch replacement: €2,500+. CRITICAL: Volvo claims transmission is "sealed for life" but experts recommend fluid change at 50,000 km to prevent issues. Manual transmission cars are significantly more reliable.
Oil consumption (2010-2015 models)€3,000 - €6,000
Early D4 engines burn oil due to poorly designed piston rings - asking for 0.5L every 500km · more· less
Early D4 engines (2010-2015, especially 2010-2011) have excessive oil consumption caused by poorly designed oil control rings that clog with carbon. Owners report adding 0.5L every 500-1,000 km. You won't see smoke because the DPF captures it. Volvo considers 1L per 1,000 miles "acceptable" but this is excessive. Solution: new pistons and rings (engine rebuild). Some cases covered by recall if oil consumption test criteria met. DIY monitoring: Check oil weekly - never let it drop below minimum. Engine rebuild cost: €3,000-6,000. Good news: Volvo remedied the oil ring design in 2016, and 2017 models have no reported issues. This is why 2010 and 2015 are years to avoid, while 2016-2017 are recommended.
Timing belt & water pump failure€900 - €1,600
D4 uses timing belt (not chain) requiring replacement every 120,000 km - interference engine · more· less
IMPORTANT: D4 engines use timing belts, NOT chains (the 3.0L and 3.2L six-cylinder engines have chains). Recommended interval: every 120,000 km or 10 years, whichever comes first. This is an interference engine - if the belt breaks, valves hit pistons causing catastrophic damage (€3,000-8,000 rebuild). Always replace water pump simultaneously (it's driven by timing belt and labor is already done). Belt + pump parts: €300-500. Labor: 4-6 hours (€600-1,100). Total: €900-1,600 at independent shop, higher at dealer. Consider also replacing tensioners, pulleys, serpentine belt during this service. Check service history - if belt replacement isn't documented and car is over 120,000 km or 10 years old, budget for this immediately.
AdBlue system issues€200 - €1,500
AdBlue injector clogs with urea crystals; car won't start if tank runs completely dry · more· less
Modern diesel XC60s use AdBlue (32.5% urea solution, 11.5L tank capacity) for emissions control. Common problem: AdBlue injector blocks with urea crystals even when tank is nearly full. One owner at 30,000 km had completely blocked injector. Temporary fix: Hot water dissolves crystals, clean and refit injector (€200-400 at independent shop). Permanent fix: Replace injector (€600-1,000+). Other issues: NOx sensor failure (€300-700), SCR catalyst failure (€1,200-1,500). CRITICAL WARNING: Never let AdBlue tank run completely dry - if it does, car won't start at all, even with jump start. Refill minimum 3L when warning appears. Prevention: Use quality AdBlue, keep fill cap area clean before refilling to prevent contamination.
Battery drain & electrical issues€200 - €1,200
Parasitic drain from window control unit, TCAM module, climate control, or auxiliary battery · more· less
XC60s suffer various electrical drains. Common culprits: 1) Window control unit not shutting off properly (should drop to 0.5mA within 30 min, but doesn't). 2) TCAM module (2022+ models) - fixed with software patch. 3) Shark fin antenna battery draining main battery. 4) Climate control unit corrosion from water damage causing parasitic draw. 5) Satellite radio module drawing current when car is off (TSB issued). 6) Faulty auxiliary battery. Solution: Dealer software update often fixes it. Individual component replacement: €200-500. Full electrical diagnosis: €100-200. Prevention: Avoid frequent short trips, take extended drives, replace main battery every 4-5 years (€150-300). Some owners install battery trickle chargers if car sits unused for weeks.
Suspension bushings & control arms€400 - €1,800
Control arm bushings wear around 100,000 km causing squeaking; dealer quotes often excessive · more· less
Control arm bushings typically need replacement around 100,000 km, earlier if driven aggressively or on rough roads. Symptoms: annoying squeak over bumps, inconsistent handling (if severely worn). Bushings-only replacement: €380-470 at independent shop. Dealers often quote €1,800+ and recommend full control arm replacement (includes bushings and ball joint). Full control arm: €600-670. DIY option: TRW control arms (OE supplier) cost €120-170 each, 2 hours per side labor. Always do wheel alignment after suspension work (€80-120). Mechanics recommend replacing ball joints at same time if bushings are worn. Front and rear may need attention. This is mostly an inconvenience issue rather than safety-critical, though severely worn bushings affect handling.
Dual mass flywheel (manual transmission)€1,300 - €2,200
DMF can last 100,000+ km but expensive to replace - always change clutch simultaneously · more· less
Manual transmission XC60s use dual mass flywheels (DMF) that dampen engine vibrations. Expected lifespan: 100,000-150,000 km if treated well. Symptoms of failure: vibration at idle, difficulty shifting, rattling noise when starting/stopping engine. Parts cost: €265-870 depending on OEM vs aftermarket. Labor: 8-12 hours to remove transmission. Total at dealer: €1,700-2,200. Independent shop: €1,300-1,700. CRITICAL: Always replace clutch at the same time (parts: €200-400, no extra labor since transmission is already out). Total clutch + flywheel job: €1,500-2,500. Prevention: Avoid riding the clutch, don't rest foot on pedal, smooth shifts, avoid slipping clutch on hills. Good news: Manual transmissions are far more reliable than the problematic automatics.
Decent reliability for a diesel SUV, but EGR and DPF demand attention
The XC60 D4 scores 97.9% in reliability surveys, outperforming the BMW X3 and Audi Q5. The D4 engine is fundamentally robust if maintained properly, but the emissions equipment (EGR, DPF, AdBlue) is the Achilles' heel. Cars driven mainly short distances will suffer repeated EGR and DPF issues. Best for: motorway commuters doing 20,000+ km/year. Avoid if: you do mostly city driving under 10 km per trip. Manual transmission is far more reliable than automatic. Years 2016-2017 are the sweet spot - avoid 2010 and 2015.
Pre-Purchase Inspection Checklist
General checks
Service history Complete Volvo dealer or specialist records essential. Verify EGR, DPF, timing belt service completed.
Tires Common size 235/60R18. Check tread depth, age (date codes), uneven wear patterns.
Cold start Must start engine completely cold. Listen for unusual noises, check for excessive smoke.
Test drive Minimum 30 minutes including varied speeds, motorway, and stop-and-go traffic. Test transmission carefully.
Body condition Check for rust (wheel arches), accident damage, paint mismatch.
Specific for this vehicle
Verify inlet manifold fire recall completed (2014-2017) THIS IS CRITICAL. Contact Volvo with VIN to confirm recall work done. If not, walk away or demand dealer completion before purchase.
Check for EGR/DPF warning lights Start car and watch for engine management light. Any EGR or DPF codes indicate expensive repairs needed.
Test power steering thoroughly Turn wheel full lock both directions at standstill and while driving. Listen for whining, check for difficulty or sudden loss of assist.
Check oil consumption history Ask owner about oil top-ups between services. Check oil level - should be between min/max. Request oil consumption test if suspicious.
Verify timing belt replacement Belt must be replaced every 120,000 km or 10 years. If no documented proof and car is older, budget €900-1,600 immediately.
AdBlue system check Verify AdBlue level, check for warning messages. Test that system doesn't show errors after 15+ minute drive.
Transmission operation (automatic cars) Drive for 20+ minutes. Feel for harsh shifts, hesitation, jerking, clunking. Powershift transmissions are particularly problematic - prefer manual or Aisin auto.
Battery and electrical system Check for any electrical warning messages. Ask if car has had battery drain issues. Verify all electrical functions work.
Ask about typical journey length Cars used mainly for short trips (under 10 km) will have DPF/EGR issues. Prefer cars with motorway commute history.
Recalls and Technical Service Bulletins
Inlet manifold fire risk (2014-2017, 2.0L diesel)CRITICAL - Verify completed
Fuel pump module failure (2008-2010)Check VIN
DPF, intake manifold, EGR recallsMultiple campaigns - verify all completed
Oil filter leak causing fire risk (2016)Check VIN
Satellite radio module parasitic drainTSB issued - software update available
The XC60 has had 33 recalls covering various issues from minor (fuel gauges) to serious (fuel leaks, gearbox jamming, airbag failures). The 2014-2017 inlet manifold fire recall is the most critical - absolutely verify completion with Volvo using VIN before purchase.
Warranty Status
Factory warranty (3 years)Expired on all 2008-2017 models
Volvo extended warrantyAvailable for purchase
Diesel emissions recallsCheck Volvo website with VIN
All first-generation XC60s (2008-2017) are outside their original factory warranty. Extended warranty may be available through Volvo dealers or third-party providers. Given the potential for expensive EGR, DPF, and transmission issues, extended warranty could provide peace of mind, though read the fine print carefully regarding diesel emission system coverage.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.