Volvo S60 recalls

On affected vehicles the High Voltage (HV) Battery may have a manufacturing defect which could cause the battery cells to overheat when the HV Battery is fully charged. In a worst-case scenario there is a risk of fire when the vehicle is parked up with a fully charged HV Battery.

Fix: Check and replace the HV Battery if necessary and install modified software.

40 vehicles · built 25 Feb 2019 to 30 Nov 2021

The rod connecting the brake pedal to the brake booster may not have been assembled correctly. The final torque might not be according to manufacturing specification due to deviations in the equipment. If the rod does disconnect the mechanical connection between brake pedal and brake booster cannot be guaranteed. In the worst-case scenario if the rod disconnects the brake pedal function cannot be guaranteed

Fix: A Volvo retailer will check and if necessary tighten the rod to correct specification.

55 vehicles · built 13 Jun 2019 to 13 Aug 2020

The passenger air bag may not have been correctly secured.

Fix: Inspect and re torque retaining bolts.

17 vehicles · built 2 Aug 2018 to 14 Jul 2023

During driving or idle the O-Ring may become twisted or break. Should this occur there could be an oil leak a message for low engine oil level displayed in the vehicle or an unusual smell in the cabin. In a worst case scenario this could cause a thermal event.

Fix: Replace O-Ring

13,701 vehicles · built 19 Oct 2021 to 13 Jul 2023

There may be a potential software error in the brake control module.

Fix: Update the brake control module software.

10,197 vehicles · built 26 Sep 2022 to 11 Jan 2023

The Engine Control Module (ECM) may prevent the combustion engine from starting.�

Fix: Download updated software.

4,755 vehicles · built 26 Apr 2021 to 29 Sep 2022

There may be an insufficient or missing welding connection in the Hydraulic Unit of the Brake System.

Fix: Replace the Hydraulic Unit.

28 vehicles · built 10 Dec 2020 to 12 Jan 2021

Pressure in the fuel tank could cause the fuel level sender to indicate fuel in the tank when it could be empty.

Fix: Update software which will allow the electronic fuel tank ventilation valve to release pressure when required.

256 vehicles · built 21 May 2021 to 19 Jul 2021

There is a risk that the 15amp fuse could blow which will prevent the low pressure fuel pump operating.

Fix: Replace the 15A fuse with a 20A fuse which can withstand this peak.

14,380 vehicles · built 28 Jun 2018 to 25 Dec 2019

There is a risk for trapped air to be in the cooling system which may result in insufficient cooling of engine components.

Fix: Add an extra degassing line (Bleeder Hose) between the cooling system radiator and the cooling system expansion tank which will evacuate the trapped air

76,945 vehicles · built 22 Oct 2013 to 12 Oct 2016

There is a risk for trapped air to be in the cooling system which may result in insufficient cooling of engine components.

Fix: Add an extra degassing line (Bleeder Hose) between the cooling system radiator and the cooling system expansion tank which will evacuate the trapped air.

15,167 vehicles · built 14 Nov 2012 to 6 Feb 2017

Potential breakage/fatigue of a flexible steel cable supporting the front seatbelt anchor point.

Fix: Replace the seat belt fastener with a new designed seat belt fastening.

170,160 vehicles · built 21 May 2010 to 14 Aug 2018

The Automatic Emergency Brake System a function of the IntelliSafe system may not always engage increasing the risk of a collision

Fix: Affected vehicles must have new software downloaded

56,385 vehicles · built 8 Feb 2019 to 10 Mar 2020

The engines plastic inlet manifold may melt and deform

Fix: Update vehicles with improved soot reducing software cleaning of TMAP and EMAP. Fit additional hoses where necessary.

• S60: vehicle count not given · built 2 Jun 2015 to 30 Jun 2016
• S60: vehicle count not given · built 20 May 2015 to 24 May 2018
• S60: vehicle count not given · built 16 Apr 2015 to 13 Oct 2016
• S60: vehicle count not given · built 14 Nov 2012 to 5 Oct 2016
• S60: vehicle count not given · built 29 Oct 2013 to 10 Apr 2016
• S60: vehicle count not given · built 15 May 2014 to 29 Jun 2018

Small cracks on the inside of a rubber fuel hose.

Fix: Replacement of affected fuel hoses.

30,777 vehicles · built 11 Apr 2015 to 30 May 2016

It has been identified by the manufacturer that the air-bag initiator does not meet specification. This can therefore result in the initiator not functioning correctly which can lead to none deployment of the air-bag. Should a collision occur then there is an increased risk of injury to the occupants of the vehicle.

Fix: Recall all affected vehicles to replace the air-bags with a new quality assured component.

1,415 vehicles · built 28 Aug 2016 to 5 Oct 2016

It has been identified there is a possibility the front seatbelt buckle stud may not have been punched correctly during production. This may result in a separation between the buckle and seatbelt bracket if the vehicle is involved in a collision.

Fix: Recall all affected vehicles to inspect the seatbelt buckle and if required to replace the seatbelt buckle.

47 vehicles · built 9 Jun 2015 to 19 Aug 2016

It has been identified that during the engine warm-up process and under certain driving/climate conditions for instance periods of high acceleration or high engine load immediately after a cold start in cold climates there is the possibility for coolant leakage or oil seepage. This can lead to the possibility in a worst-case scenario of smoke or a slow developing fire in the engine compartment. However the driver will receive a warning message on the Driver�s Information Module indicating a low coolant level.

Fix: Recall all affected vehicles to modify the coolant bypass valve and install a new exhaust manifold gasket.

3,192 vehicles · built 5 Jul 2010 to 17 Apr 2015

Involved vehicles may have a software issue which could cause the engine to momentarily cut-out and restart while driving. This could also cause disturbances in some electrical systems such as shut down of the instrument cluster infotainment system and loss of power steering assistance.

Fix: Recall the vehicles that are likely to be affected and upgrade the software of the control units.

• S60: 7,237 vehicles · built 20 Apr 2015 to 11 Feb 2016
• S60: 7,237 vehicles · built 20 Apr 2015 to 3 Sep 2015

Fuel gauge may not show correct level

Fix: The remedy is not yet available for all models. Until a remedy is available the manufacturer advises to maintain fuel level above approx one third.

1,109 vehicles · built 21 Nov 2014 to 13 Apr 2015

Fuel gauge may not show correct level

Fix: The remedy is not yet available for all models.. Until a remedy is available the manufacturer advises to maintain fuel level above approx one third.

2,743 vehicles · built 21 Nov 2014 to 17 Apr 2015

Fuel gauge may not show correct level

Fix: Dependent on affected Model update software. Until updated the manufacturer advises to maintain fuel level above approx one third.

• S60: 5,354 vehicles · built 31 Mar 2015 to 11 Dec 2015
• S60: 5,354 vehicles · built 16 Apr 2015 to 11 Dec 2015

Vehicles with manual gearboxes and start/stop functionality have Parking Brake Module (PBM) software that may allow the parking brake to unintentionally release. The unintended release of the parking brake can only occur when the engine is running and the gearstick moved so it will happen when the vehicle is attended.

Fix: Recall the vehicles that are likely to be affected to download upgraded Parking Brake Module (PBM) software.

2,146 vehicles · built 7 Jun 2011 to 30 Jan 2015

The auxiliary drive belt tensioner can suffer from premature wear which may cause it to fail. This can lead to loss of steering power assistance and a slight possibility of loss of drive should the drive belt or tensioner invade the cambelt area.

Fix: Recall the vehicles that are likely to be affected to replace the auxiliary drive belt and tensioner.

3,134 vehicles

Volvo's quality follow-up procedures have identified an issue with a limited number of S60 & V60 Volvos (MY2013). The securing screws for the inner A-pillar panels may have been torqued incorrectly. This could cause the A-pillar panels to crack and this may affect the attachment of the trims during a collision should the inflatable curtain be activated. If the trims become detached they could cause injury to the occupants in the front seats. The corrective action is to replace both A-pillar trims as well as the securing screws.

Fix: Replace both trim panels and screws.

70 vehicles

There could be a sudden and unexpected failure of the bottom end of the engine because of a non-conformity during production of the connecting rods.

Fix: Recall the vehicles that are likely to be affected to replace the engine.

6 vehicles

Some vehicles may have had excessive underbody protection applied which when drying. could have formed small stalactite shaped formations. These formations may have formed close to the underbody fuel lines and could damage them and cause a fuel leak. Due to the positioning of the fuel lines escaping fuel or fuel vapour could potentially lead to a fire.

Fix: Inspect all vehicles and cut any stalactite shaped formations off. If the fuel line is damaged it will be replaced. Only 1% of vehicles are expected to have any damage to the fuel line.

481 vehicles · built 10 Jan 2012 to 3 Feb 2012

It has been identified that the wiring harness for the SRS system may not have been correctly attached to the front seat frames. It is possible that continued adjustment of the seat position may cause the harness to become detached. If this should occur a warning light will illuminate on the instrument panel warning the driver of a fault with the SRS system. However in this condition the front and side airbags may not deploy if the vehicle is involved in a collision.

Fix: Recall all affected vehicles for an inspection of the wiring harnesses and ensure that it is correctly routed and secured. If not then reroute and securing of the wiring harness.

9,330 vehicles

It is possible that the upper power steering return line may become detached which will result in the loss of power steering fluid. This will result in fluid leaking onto the road surface leaking into the engine bay and the driver experiencing heavy steering.

Fix: Recall the affected vehicles for the replacement of the power steering return line.

213 vehicles

It is possible that due to a software issue fuel may not be pumped from one side (passive side) of the fuel tank to the other side (active side). This can occur even if the fuel gauge is reading a quarter full. If fuel transfer is not possible it may cause the engine to stall.

Fix: In the first instance drivers are requested to keep their vehicle's fuel tanks above half full. Then all affected vehicles will be recalled for the upgrade of the software.

1 vehicle

Vehicles may have an incorrectly manufactured fuel supply line which could lead to fuel leakage. In worst cases the fuel line could become detached and the engine would stall without warning to the driver.

Fix: Replace fuel supply line.

1 vehicle

It is possible that the driver's and passenger's front powered seats may not be fitted with the front stop lug. The lug restricts the movement of the seats and if not fitted it is possible to position the seats too far forward or backwards. This could increase the chances of injury should the vehicle be involved in an accident.

Fix: Recall all affected vehicles to inspect for fitment of the lugs and if found to be missing fit new lugs.

103 vehicles

On certain five cylinder engines it is possible that the high pressure fuel pipes may not have been correctly installed and may leak. This should be identified by a smell of fuel from the engine bay. However it is possible that in extreme cases an engine bay fire could occur.

Fix: Recall all affected vehicles and replace the high pressure pipes.

845 vehicles

When driving at low speeds a fault within the software calibration of the engine and transmission control modules may lead to a drop in the engine idle speed when braking or releasing the accelerator. In extreme cases this may result in the engine cutting out without warning.

Fix: Recall the vehicles that are likely to be affected to upgrade the engine/transmission software.

64 vehicles

It is possible that an electrical short circuit within a connector could result in the illumination of the Airbag System Service Required message and Supplemental Restraint System warning lamp on the dashboard. Should this occur the driver's airbag would not deploy as intended if the vehicle is involved in a collision.

Fix: Recall all affected vehicles to check and rework the connector.

6,844 vehicles

On a small number of S60 cars it is possible that secondary bonnet catch will not lock in the closed position correctly. If the bonnet is not closed correctly it is possible that the secondary bonnet catch will not secure the bonnet which could result in it opening unintentionally.

Fix: Recall the affected vehicle for inspection and adjustment to the lock if required.

233 vehicles

On effected petrol and diesel engines a spring clamp on the radiator hose connecting it to the water inlet pipe may be insecure. If not rectified the engine may lose coolant overheat seize and suddenly slow the vehicle rapidly to a halt.

Fix: Recall the vehicles that are likely to be affected to have the radiator hose adequately secured.

326 vehicles

The electric cooling fan control unit's metal cover may not have the correct corrosion protection. Should corrosion occur water may enter the control unit causing an electrical malfunction and in extreme cases cause a fire in the engine compartment.

Fix: Recall the vehicles that are likely to be affected to fit an improved fan assembly.

388 vehicles

Volvo have identified that due to certain climatic conditions the electric cooling fan may overheat and in extreme cases cause a fire within the engine bay.

Fix: Recalled vehicles will have the cooling fan assembly replaced.

35,024 vehicles

The nut securing the front suspension strut lower ball joint to the control arm may loose its axial tension due to an out tolerance condition. This could adversely affect the directional control of the vehicle.

Fix: Fit a modified ball joint to control arm securing nut.

9,735 vehicles