Swedish premium estate with a reputation for safety and comfort. The D4 diesel offers strong fuel economy (50+ mpg real-world) but comes with typical modern diesel complexities. Main concerns: EGR cooler clogging (well-documented VEA diesel issue), DPF blockage on short trips, turbo actuator sticking, and rear brake pads wearing unusually fast due to adaptive cruise control. Timing belt requires replacement at 120,000 km. Powershift automatic transmission less reliable than manual. Check for coolant leak recall (2010-2015 models) and verify EGR has been addressed under goodwill.
Expected Annual Maintenance Costs
€1,200 - €2,000/year
15,000 km/year
Fixed costs
€700-1,100
Risk buffer
€500-900
What Can Break
bars = likelihood
EGR cooler/valve failure€800 - €1,400
Well-known D4 VEA diesel issue - EGR cooler clogs with soot causing limp mode · more· less
This is the most documented issue with D4 engines. The EGR cooler becomes blocked with carbon deposits, causing check engine light, limp mode, and reduced performance. Volvo dealers acknowledge this as a common problem and have updated parts/software. Some owners report goodwill repairs even outside warranty if full Volvo service history exists. Typically occurs between 50,000-100,000 km. Repair involves replacing EGR valve, cooler, and pipework with updated parts plus software update. Dealer cost €800-1,400, though Volvo has covered some repairs at no cost.
Common on cars used for short trips - requires regular motorway runs for regeneration · more· less
The D4 uses a DPF designed as a "service item" at 120,000 km according to Volvo. Short trips prevent proper regeneration, causing soot buildup. Active regeneration takes 10-20 minutes at speed. If DPF becomes fully blocked, cleaning costs €250-400, but replacement is €800-1,200. Pattern (aftermarket) DPFs available for €250-300. Prevention: regular motorway drives (30+ minutes at 100+ km/h), avoid only city driving, ensure AdBlue system functioning properly.
Actuator sticks from gentle driving, causes EPC warning and limp mode · more· less
The turbo actuator tends to stick if car driven too gently or only short trips, as carbon builds up. Symptoms: EPC light, limp mode, loss of boost pressure. Volvo won't sell actuator separately. Actuator-only repair at specialist: €500-700. If turbo internals damaged, full replacement €1,500-2,500. Typical failure: 80,000-120,000 km. Prevention: occasional spirited driving, premium fuel, regular long runs. Some owners report turbo issues as early as 80,000 km with symptoms of loss of power, black smoke, and whistling noises.
Timing belt replacement (scheduled)€800 - €1,500
Required every 120,000 km or 10 years - this is an interference engine · more· less
Volvo recommends timing belt replacement at 120,000 km (75,000 miles) or 10 years. This is an interference engine - if belt fails, valves hit pistons causing catastrophic damage (€3,000-6,000 repair). Always replace water pump, tensioners, and pulleys at same time. Dealer cost €1,200-1,500, independent specialist €800-1,200. Budget €80-120/year if amortized. Critical: verify timing belt history before purchase on high-mileage cars.
Rear brake pads premature wear€200 - €450
Adaptive cruise control uses rear braking primarily - pads wear at 30,000-50,000 km · more· less
This is a well-known issue across Volvo models with adaptive cruise control. The system preferentially uses rear brakes, causing disproportionate wear. Rear pads typically need replacement at 30,000-50,000 km while fronts still have 70%+ life. Pre-2010 electronic parking brake (EPB) also doesn't fully release pads. Volvo introduced updated springs in 2020 to help pads retract better. Cost: rear pads €150-250 parts, total €200-450 with labor. Some owners report needing rear pads every 30,000 km, which is now "considered normal by Volvo."
Dual-clutch Powershift known for jerky shifts, overheating, clutch slippage · more· less
If your V60 has Powershift automatic (check for "MPS6" label under bonnet), be aware this transmission is "known to be very problematic." Common issues: jerky shifts, slippage, overheating on hills or in traffic, clutch wear. Overheating causes shaking/vibration. Don't hold car on hills with accelerator - use foot brake to prevent overheating. Fluid changes every 3 years essential. Manual gearbox much more reliable. Repair costs: clutch replacement €1,500-2,500, mechatronics €2,000-4,000. The Aisin 6-speed automatic (not Powershift) is considered more reliable.
Diesel injector failure€800 - €2,000
Injectors fail after 120,000-150,000 km causing rough idle, misfires · more· less
D4 diesel injectors typically fail between 120,000-150,000 km. Symptoms: rough idle, vibrations, lack of torque below 1,500 rpm, check engine light. Continental/VDO injectors are cheapest option at €200 each. Often not repairable - must be replaced. Labor-intensive job requiring specialist. Total cost: €200-250 per injector plus labor (approximately €100-150/hour for 2-4 hours). Budget €800-2,000 depending on how many injectors need replacement. This is not a DIY job due to fire risk and complexity.
Auxiliary battery failure€200 - €450
Small 12V battery fails causing loss of start/stop, power steering warnings · more· less
The auxiliary (start/stop) battery is a small 12V battery located under passenger-side cowl. Fails at 4-6 years causing loss of start/stop function, park assist, and sometimes power steering warnings. Symptoms: "START/STOP SUPPORT BATTERY" warning, power steering malfunction messages (99% of steering issues are actually auxiliary battery). The aux battery doesn't charge until main battery is fully charged. Dealer replacement €350-450, DIY with CTEK charger €200-300. Preventive: use CTEK charger monthly to maintain both batteries, especially if car sits for 4-5+ days.
Sensus infotainment freezing/glitches€0 - €800
Screen freezes, no sound, unresponsive - usually fixable with software reset · more· less
Common issues: center display freezing (affecting radio, indicators, parking sensors), no sound, unresponsive touchscreen, system requiring 10 minutes to start working. Usually software-related. Solutions: (1) Soft reset - press and hold Home button 20-30 seconds until restart, (2) Allow car to sleep 30 minutes after locking, (3) Disconnect battery 2-3 minutes, (4) Dealer software update (often free under warranty). Rare hardware failures (display unit) cost €600-800 to replace. Most issues resolved by software updates - ask dealer to install latest version.
AC compressor failure€1,200 - €1,500
Compressor typically fails after 100,000-120,000 km from moisture/clogs · more· less
AC compressor failure relatively common after 100,000 km. Causes: moisture or clogs in system placing stress on compressor. Symptoms: no cold air, unusual noises from compressor. Compressor replacement €1,200-1,500 including labor (approximately 4 hours). If evaporator also needs replacement, cost jumps to €3,000-5,000 as dashboard must be removed (10+ hours labor). Simple fixes like regas cost €80-150. Prevention: run AC regularly year-round to maintain seals and circulation.
Typical modern diesel complexities with above-average reliability
The V60 D4 is a solid car but shares the common issues of modern diesels: EGR, DPF, and turbo problems. The D4 VEA engine's EGR issue is well-documented with many goodwill repairs from Volvo. Avoid cars with only short-trip history (DPF risk) and Powershift automatic transmission. Manual gearbox examples with full Volvo service history are most reliable. Rear brake wear is abnormally fast but predictable. Overall reliability is average to good for the segment - comparable to BMW 3 Series and Mercedes C-Class, slightly behind Toyota/Lexus.
Pre-Purchase Inspection Checklist
General checks
Service history Complete Volvo dealer or specialist records essential. Verify oil changes at proper intervals (max 18,000 km).
Tires Check tread depth, age (date codes), and uneven wear. Common sizes: 225/50R17, 235/45R17.
Cold start Must start engine completely cold. Listen for unusual diesel rattle or turbo noises.
Test drive Minimum 30 minutes including motorway speeds to warm DPF and gearbox fully.
Body condition Check for rust, accident damage, panel gaps. Volvos generally rust-resistant.
Specific for this vehicle
Check for EGR-related check engine light or limp mode During test drive, watch for check engine light, limp mode, or reduced power. Ask if EGR has been replaced under goodwill.
DPF regeneration frequency - ask owner Ask how car has been used. Short trips only = high DPF clogging risk. Look for DPF warning lights or messages.
Rear brake pad wear - inspect during viewing Ask to see rear brake pads. If car has adaptive cruise and pads are at 30-50% at moderate mileage, this is normal for V60.
Verify coolant leak/fire recall completed (2010-2015) Cars built July 2010 - April 2015 had coolant leak recall that could cause engine fire. Verify with Volvo using VIN.
Check timing belt replacement history Critical on cars over 120,000 km or 10 years old. If no proof of replacement, budget €800-1,500 immediately.
Test auxiliary battery - start/stop function Verify start/stop works properly. If "START/STOP SUPPORT BATTERY" warning appears, auxiliary battery needs replacement.
Powershift automatic - feel for jerky shifts If automatic, verify which type (Powershift MPS6 vs. Aisin). Drive for 20+ minutes, feel for jerking, hesitation, shuddering.
Sensus infotainment - test all functions Test radio, navigation, phone connection. Press every button. Look for signs of freezing or lag.
Turbo boost - test acceleration at motorway speed At 80-100 km/h, accelerate firmly. Car should pull strongly without hesitation, smoke, or whistling noises.
AdBlue system - verify no warnings Check AdBlue level and that no system warnings are present. Top-up costs €10-20 per refill.
Recalls and Technical Service Bulletins
Coolant leak/engine fire risk (July 2010 - April 2015)Verify completed
Fuel hose cracking (April 2015 - March 2016)Verify completed
Front seat belt integrity (Sept 2015 - Aug 2015)Verify completed
Brake vacuum line chafing (various models)Verify completed
Power steering software issue (Jan-Feb 2016)Verify completed
Fuel gauge software error (May 2014 - Dec 2015)Software update
EGR system - multiple TSBs for D4 VEA enginesCheck with dealer
Contact Volvo dealer with VIN to verify all recalls completed. The coolant leak recall (2010-2015) is most critical due to fire risk. EGR issues on D4 engines may be covered by goodwill even outside warranty if full Volvo service history exists - worth asking dealer.
Warranty Status
Original factory warranty (UK/Europe)3 years / 100,000 km
Rust perforation warranty12 years from delivery
Extended warranty availabilityMust be purchased within original 3-year period
All 2010-2018 V60s are now outside original factory warranty. Volvo extended warranty can only be purchased if car is still within original 3-year period. Third-party warranties available from providers like Warranty Direct, MotorEasy (UK), or similar European providers. Check if previous owner purchased extended warranty that may still be active. Note: Some D4 EGR repairs have been covered as goodwill by Volvo even outside warranty.
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.