Volvo XC60: known issues to watch out for

The Volvo XC60 is a popular SUV known for its safety, comfort and Scandinavian design, but this model also has technical points of attention that owners and potential buyers can run into. Certain versions and model years show issues you are better off knowing about before you invest or notice a fault. These range from engine problems to electronics and suspension. Anyone who recognises the weak spots can better assess whether a used car is reliable and which maintenance deserves priority.

Why even a reputable brand deserves a critical look

Volvo has built up a solid reputation, especially in terms of safety and durability. Even so, the XC60 remains susceptible to wear and design choices that cause problems in the long run. The same goes for every car. Owners appreciate the spacious cabin, the versatile AWD system (four-wheel drive) and the extensive driver assistance systems, but also report faults ranging from annoying to expensive. If you know in advance where the pain points lie, you can search more specifically for a well-maintained example and avoid disappointment. Some issues are specific to the first generations. Others occur across all model years. Car problems with Volvo are well documented, allowing you as a buyer or owner to get started well prepared.

Generations and model years: differences in vulnerability

The XC60 appeared in 2008 as the first generation and was replaced by the second generation in 2017. The oldest models up to 2012 regularly suffer from software failures in the infotainment system and electronics, while later examples score better on the reliability of sensors and display. Engine choice also plays a role: diesel versions with common-rail injection more often show problems with the particulate filter and EGR valve (exhaust gas recirculation valve) than petrol models. The second generation benefits from more refined mild-hybrid technology and improved software. Nevertheless, this generation is also not free from complaints about the automatic gearbox and electronic assistance systems. When buying a used car, always check the model year and maintenance history to better assess the risks.

Engine and drivetrain: EGR, DPF and turbo under fire

Many diesel versions of the XC60 struggle with contamination of the EGR valve (exhaust gas recirculation valve), especially when the car mainly makes short trips. The valve becomes clogged with soot, which leads to a rough-running engine, higher fuel consumption and sometimes a warning light. Regular cleaning or replacement of the EGR valve helps, but the complaint remains persistent with intensive city use. The diesel particulate filter (DPF, which traps soot particles from the exhaust) also causes problems: if the regeneration cycle does not take place due to too few motorway kilometres, the filter becomes saturated. This results in power loss and expensive replacement costs.

Turbo problems occur on both diesel and petrol versions. Owners report that the turbo can start to leak or whistle after 150,000 to 200,000 kilometres. This indicates wear of bearings or seals. Early detection through regular checks of oil level and quality can prevent more serious damage. On four-cylinder turbo petrol models, specialists also see fuel pump and ignition coil failures, especially on older generations.

Practical tips for drivetrain health

• Regularly drive longer distances on the motorway to stimulate DPF regeneration.
• Check the engine oil level every month and change the oil according to the factory schedule.
• Have the EGR valve inspected preventively during the annual service.
• Watch for smoke, loss of power or irregular idling as early warning signs.

Automatic gearbox: juddering and delayed response

The Aisin eight-speed automatic in many XC60 models has a fairly good reputation, but in some examples shows symptoms such as juddering when changing gear, delayed response when pulling away or a jerky feel at low speed. These issues mainly crop up when the transmission fluid has not been changed for too long or when the mechatronics unit starts to fail. Volvo advises changing the transmission fluid at around 60,000 kilometres, even though the service booklet sometimes says “lifetime”. In practice, a fluid change significantly extends the service life.

More serious problems manifest themselves as chains of error codes in the on-board computer, a flashing warning light or even a limp-home mode in which the gearbox only uses a few gears. Repairing the mechatronics or a full gearbox overhaul is expensive, often between 2,000 and 4,000 euros. When buying used, check whether any service history is available for the transmission and test thoroughly that gear changes are smooth and prompt.

Electronics and infotainment: Sensus and sensor troubles

The Sensus infotainment system in the first-generation XC60 suffers from software bugs that cause the screen to freeze, Bluetooth connections to drop or the audio system to cut out unexpectedly. Firmware updates via the dealer solve some of these problems. Not all owners, however, notice a lasting improvement. The second generation received a larger touchscreen and Google integration, which improves stability but is not immune to glitches. Regular software updates remain necessary.

In addition, sensors and cameras for parking assistance, blind-spot monitoring and adaptive cruise control regularly show faults. Dirt, moisture or damage to sensors causes warning messages or failure of assistance systems. Clean the sensors at every wash and have defective units replaced immediately to limit safety risks. Problems also occur with the 360-degree camera: loss of image or distorted display indicates a defective camera module.

Chassis and suspension: control arms and shock absorbers

The front control arms and associated rubber bushes on the XC60 wear faster than expected, especially on models that cover high mileages or regularly drive on poor road surfaces. Symptoms include knocking noises over bumps, nervous steering or uneven tyre wear. Replacing control arms is labour-intensive and costs several hundred euros per axle. During a test drive, check that the chassis feels tight and that no knocking noises are audible over potholes or speed bumps.

The shock absorbers also lose their damping performance at higher mileages, leading to a wallowy ride and longer braking distances. Always replace shock absorbers per axle to maintain balance. Steering rack and power steering rarely cause major problems, but do check for power-steering fluid leaks around the hoses and pump.

Brakes and safety: wear and ABS issues

Brake wear on the XC60 is normal, but owners notice that brake discs, especially at the rear, corrode quickly when the car stands still a lot. Corrosion attacks the disc edge and can lead to uneven braking performance. Regularly brake firmly to scrub off rust and check disc thickness at every service. The ABS sensor (which controls the anti-lock braking system) at the wheels is also sensitive to dirt and moisture, causing warning lights and loss of traction control.

The electronic parking brake shows faults on some examples, especially in cold or damp conditions. Regular use and a software update can help. Have the parking brake checked if it reacts slowly or generates a fault code.

Interior and bodywork: creaks and leaks

Owners report creaking noises from the dashboard or centre console, often caused by loose clips or wear of plastic parts. This is annoying but not technically serious. Electrically adjustable seats can also develop faults: the motor jams or the memory function for seat positions stops working. Repair requires replacement of the seat motor or control module.

Water ingress occurs occasionally, especially around the panoramic roof seals or tailgate. Blocked sunroof drains allow water to seep inside. This can lead to moisture damage and electrical faults. Clean the drains annually and check rubber seals for cracks. Faulty electric windows usually point to broken window regulators or switches, a relatively simple repair.

Maintenance and prevention: what works

Regular maintenance is the key to a reliable XC60. Follow the factory maintenance schedule. In addition, consider shorter intervals for engine oil and transmission fluid, especially with intensive use. Check coolant, brake fluid and power-steering fluid every six months and replace them according to advice. Clean sensors and cameras at every wash to keep assistance systems fault-free.

Invest in quality fuel, especially for turbo versions, and regularly fill up with premium unleaded for optimal combustion. Have fault codes read out immediately and resolve problems early before they grow into costly repairs. Those who work preventively and stay alert to symptoms keep the XC60 healthy for longer and avoid major financial setbacks.

Recognising and tackling symptoms

Early detection makes all the difference. Watch out for warning lights, unusual noises, changes in driving behaviour or smells in the cabin. A diesel smell or smoke indicates problems with the diesel particulate filter (DPF, which traps soot particles from the exhaust) or the EGR valve (exhaust gas recirculation valve). Juddering or delayed response when changing gear calls for a transmission inspection. Knocking or rattling noises under the car point to chassis issues. Software updates for infotainment and safety systems are available via the dealer and solve many electronics-related complaints.

If you are unsure about the cause, have the car checked with diagnostic equipment. Many garages have Volvo-specific software that goes deeper into the systems than generic scanners. Keep all maintenance documentation and write down complaints so you can spot patterns and communicate more effectively with the mechanic.

Buying advice for a used XC60

If you are considering a used XC60, first check the service book and the mileage. Look for evidence of EGR cleaning, DPF regenerations, transmission fluid changes and software updates. Take a test drive in which you pay attention to gearshift performance, steering feel, braking and noises from the engine and chassis. Test all electronic functions: infotainment, climate control, seat adjustment, assistance systems and electric windows.

Inspect the bodywork for rust around wheel arches and sills. Check the condition of the tyres for uneven wear, which indicates incorrect alignment or worn components. Ask about any warning lights or fault codes and, if in doubt, have the car inspected by an independent specialist. Ideally, choose an example with a full dealer history and recent service.

Checklist for the viewing

• Complete service book with stamps or invoices
• Test drive focusing on transmission, brakes and steering
• Test of all electronic systems and infotainment
• Inspection of engine for leaks, smoke and noises
• Check of chassis for play, leaks and damage
• Tyre check for tread depth and wear pattern
• Ask about known issues for the specific model year and engine type

Pros and cons at a glance

The Volvo XC60 offers comfort, safety and versatility, but it also has weak spots you should not ignore. Anyone who chooses with care, maintains the car properly and stays alert to symptoms can enjoy this popular SUV for years with relatively few problems. Diesel models require extra attention for EGR and DPF, while petrol versions are less sensitive to these specific complaints. The automatic gearbox deserves preventive maintenance and early action when symptoms appear. Electronics remain a point of attention, but regular updates and careful handling of sensors help limit problems. When buying, opt for a well-documented example and invest in regular professional maintenance. That way the XC60 remains a reliable and pleasant companion for work, family and longer journeys.