AWD angle gear (bevel gear)
usually 100,000–200,000 km · Medium risk
Signs: Clunk, AWD not engaging, oil leak
Fix: Replace angle gear / seals; change oil
€600–2,000
Common faults, service intervals and costs
Volvo S60 I
2000–2009 · Volvo S60 1
1
engines covered
10
known faults
6,208
roadworthiness tests in the statistics
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
The Volvo S60 I was built from 2000 to 2009.
For this generation we cover 1 engines and 10 known faults, each with the mileage range where it usually appears.
The most expensive known risk is Automatic gearbox (XC90 T6 / some 5-speed): it usually appears at 120,000–220,000 km and costs €300–3,000 to fix.
In UK roadworthiness tests in 2024, at 250+ thousand km this model most often failed on: lights, wipers and visibility (28.5 %), brakes (19.7 %), suspension (14.3 %). It fails less often than average on: suspension, body and corrosion, exhaust, emissions and leaks.
Engines
| Engine | Fuel | Timing drive | Oil |
|---|---|---|---|
| 2.0 / 2.4 D / D3 / D4 / D5 5-cyl (Volvo D5) | Diesel | Belt · 120,000 km / every 96 mo | 5W-30 / 0W-30 · ACEA A5/B5 / C2 · ~6.0 L · every 15,000 km |
Faults typical of this model
Automatic gearbox (XC90 T6 / some 5-speed)
usually 120,000–220,000 km · Medium risk
Signs: Slipping, harsh shifts
Fix: Fluid flush; rebuild
€300–3,000
CEM / electrics
usually 100,000–250,000 km · Wear part
Signs: Random electrical faults
Fix: Diagnose; replace module
€200–700
Faults by engine
2.0 / 2.4 D / D3 / D4 / D5 5-cyl (Volvo D5)
Swirl flaps / intake manifold (pre-2007)
usually 120,000–220,000 km · Medium risk
model years 2001–2007 only
Signs: Engine light, power loss
Fix: Replace manifold / actuator
€400–1,000
EGR valve / cooler
usually 120,000–220,000 km · Medium risk
Signs: Limp mode
Fix: Clean or replace
€300–900
Crankcase breather (oil trap) clogging
usually 150,000–250,000 km · Medium risk
Signs: Oil leaks from seals, crankcase pressure
Fix: Replace oil trap / breather
€150–400
Turbo actuator
usually 150,000–250,000 km · Medium risk
Signs: Limp mode
Fix: Replace actuator
€300–800
Gearboxes
Manual
Clutch wear
usually 120,000–200,000 km · Medium risk
Signs: Slipping, high bite point
Fix: Replace clutch kit
€500–900
Dual-mass flywheel
usually 150,000–220,000 km · Medium risk
Signs: Rattle at idle, vibration pulling away
Fix: Replace with clutch
€700–1,400
Geartronic (Aisin / GM)
Aisin TF-80SC harsh shifts / valve body
usually 120,000–220,000 km · Medium risk
Signs: Harsh 2–3 / 3–4 shifts, flare
Fix: Fluid flush; valve body
€300–1,500
Scheduled service
Intervals and typical prices for the 2.0 / 2.4 D / D3 / D4 / D5 5-cyl (Volvo D5) engine. Other engines differ in oil, timing drive and some filters; the app gives the exact plan.
| Item | Interval | Typical price |
|---|---|---|
| Engine oil + oil filterEngine | every 15,000 km or every 12 months | €70–150 |
| Cabin (pollen) filterClimate | every 15,000 km or every 12 months | €15–40 |
| Brake fluidBrakes | every 24 months | €50–95 |
| A/C service (regas + desiccant)Climate | every 24 months | €70–150 |
| Air filterEngine | every 30,000 km or every 24 months | €15–45 |
| Fuel filterFuel | every 30,000 km or every 24 months | €40–110 |
| Glow plugsEngine | every 100,000 km | €120–300 |
| Auxiliary (serpentine) beltEngine | every 120,000 km | €70–180 |
| Timing belt kit + water pumpEngine | every 120,000 km or every 96 months | €450–900 |
| Coolant replacementCooling | every 150,000 km or every 96 months | €70–150 |
| Manual gearbox oilTransmission | every 150,000 km | €60–130 |
| Front brake padsBrakes | usually at 30,000–60,000 km | €60–150 |
| Front brake discs + padsBrakes | usually at 60,000–120,000 km | €150–320 |
| Rear brake padsBrakes | usually at 50,000–90,000 km | €50–130 |
| Tyres (set of 4)Wheels | usually at 40,000–60,000 km | €320–700 |
| Wiper bladesBody | checked at service | €20–50 |
| 12V batteryElectrical | checked at service | €100–220 |
Roadworthiness tests by mileage
Share of tests in the United Kingdom (DVSA MOT, 2024) that this model failed because of each system. Bold red means more often and green less often than an average car of the same age and mileage. Sample: 6,208 tests.
| thousand km | 100–150 | 150–200 | 200–250 | 250+ |
|---|---|---|---|---|
| Brakes | 13.2 % | 15.8 % | 18.9 % | 19.7 % |
| Suspension | 7.8 % | 10.5 % | 10.7 % | 14.3 % |
| Steering | 2.5 % | 4.8 % | 4.8 % | 5.8 % |
| Tyres and wheels | 5.8 % | 7.9 % | 7.8 % | 7.6 % |
| Lights, wipers and visibility | 20.0 % | 25.6 % | 25.4 % | 28.5 % |
| Body and corrosion | 4.9 % | 4.6 % | 4.9 % | 5.7 % |
| Exhaust, emissions and leaks | 2.1 % | 2.0 % | 3.7 % | 3.5 % |
Owner complaints in the US
Which systems owners reported to the US agency NHTSA and at what mileage. Complaints are not confirmed faults and some relate to recalls. Sample: 827 complaints.
Other generations
Volvo S40 / V50 2004–2012Volvo S60 / V60 I 2010–2018Volvo S60 / V60 II 2018–Volvo S90 / V90 2016–Volvo S80 II 2006–2016Volvo S40 / V40 I 1995–2004
Sources and notes
Faults, intervals and prices are indicative and collected from public sources and owner experience; always rely on the service book and a qualified workshop. Test statistics: DVSA – Anonymised MOT tests and results, Open Government Licence v3.0. Owner complaints: NHTSA ODI (public domain). Recalls: DVSA Vehicle Safety Branch Recalls Database, OGL v3.0. Brand and model names are trademarks of their owners and are used only to describe the vehicles.
Updated 07/10/2026