The 2001 Volvo S60 with the 2.4L inline-5 is a comfortable, safe Swedish sedan with a fatal flaw: catastrophic PCV system failures that destroy engines. When maintained obsessively, they're solid daily drivers, but deferred maintenance turns expensive fast.
PCV System Failure Leading to Catastrophic Engine Damage
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Heavy oil consumption (1 qt per 500-1000 miles), Blue smoke from exhaust on startup or acceleration, Oil sludge buildup visible under oil cap, Rough idle and loss of power, Check engine light with lean codes (P0171/P0174)
Fix: The PCV breather box clogs, causing crankcase pressure to force oil past piston rings. Neglected cases score cylinder walls requiring full engine rebuild or replacement. Early catch: clean PCV system (4-6 hours). Advanced damage: short block or complete rebuild (18-25 hours labor plus machine work).
Estimated cost: $800-1,500 preventive cleaning; $4,500-8,000 full rebuild/replacement
Automatic Transmission Oil Cooler Line Failure
Common · high severity
Typical onset: 100,000-180,000 mi
Symptoms: Transmission fluid leaking from radiator area, Pink or red coolant in overflow tank (cross-contamination), Slipping transmission or delayed engagement, Milky transmission fluid on dipstick, Overheating transmission
Fix: Steel transmission cooler lines rust through where they connect to the radiator, allowing coolant and ATF to mix. Requires new cooler lines, radiator flush, transmission flush, sometimes new radiator if internal cooler failed. Caught early: 3-4 hours. With trans damage from coolant contamination: add transmission rebuild (12-16 hours).
Estimated cost: $600-1,200 lines only; $2,800-4,500 with transmission damage
Transmission Mounts Collapse
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Clunking when shifting from park to drive or reverse, Vibration at idle in gear, Excessive drivetrain movement visible during acceleration, Shifter feels notchy or catches
Fix: Upper torque mount and side mounts deteriorate, allowing excessive engine/trans movement. Requires lifting engine slightly to access. Replace all three mounts as a set. 2.5-3.5 hours labor.
Estimated cost: $450-750
ETM (Electronic Throttle Module) Failure
Occasional · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Sudden limp mode with reduced power, Idle surging or hunting between 500-1500 RPM, Check engine light with throttle position codes, Car won't rev above 3000 RPM, Intermittent stalling at stops
Fix: Throttle body assembly with integrated electronics fails due to internal wear and carbon buildup shorting contacts. Must replace entire ETM unit (not cleanable). Requires VIDA scan tool for adaptation after install. 1.5-2 hours labor.
Estimated cost: $650-950
Front Lower Control Arm Bushings Deteriorate
Common · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: Clunking over bumps from front end, Wandering steering or poor tracking, Uneven tire wear on inside edges, Steering wheel off-center after alignment
Fix: Volvo uses pressed-in bushings that separate from control arms. Most shops replace entire control arms rather than pressing bushings (specialized tooling required). Both sides recommended. Alignment required after. 3-4 hours labor.
Estimated cost: $650-1,000
Fuel Pump Failure
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: No-start condition with crank but no fire, Intermittent stalling when fuel tank below 1/4 full, Whining noise from rear seat area, Loss of power under acceleration, Hard starting when hot
Fix: In-tank fuel pump assembly fails, often after running low on fuel repeatedly (fuel cools pump). Requires dropping fuel tank or removing rear seat and cutting access panel. Includes new fuel filter. 3-4 hours labor.
Estimated cost: $600-900
Owner tips
Clean PCV breather box every 30,000 miles religiously—this prevents the engine-killer issue
Use synthetic oil and 5,000-mile intervals maximum; sludge is this engine's enemy
Inspect transmission cooler lines annually for rust; replace proactively at 100k miles
Keep fuel tank above 1/4 to extend fuel pump life
Budget $1,500/year for maintenance and repairs after 100k miles
Only buy if full service records prove obsessive PCV maintenance and transmission cooler lines have been replaced; otherwise you're gambling on a $6,000 engine rebuild.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 21V766000
2021-09-30
Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 20V681000
2020-11-04
Volvo Car USA LLC (Volvo Car) is recalling certain 2001-2003 S80 and S60 vehicles sold or ever registered in Alabama, Arkansas, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, Oklahoma, South Carolina, Tennessee, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands. The driver side frontal air bag inflator may rupture, sending metal fragments into the passage compartment, when the driver side air bag is deployed.
Consequence: Metal fragments can strike vehicle occupants increasing the risk of serious injury or death.
Remedy: Volvo Car will notify owners, and dealers will replace the driver side air bag module, free of charge. The recall began April 20, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo Car's number for this recall is R10058.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.
Consequence: IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
ON CERTAIN VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF ARIZONA AND NEVADA, DUE TO THE COMBINATION OF FUEL QUALITY AND CLIMATE CONDITIONS, THE FUEL PUMP MAY, IN CERTAIN CASES, EXPERIENCE A REDUCED FUNCTIONALITY. THE MOST COMMON SYMPTOMS WOULD BE FUEL ODOR.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL PUMP FREE OF CHARGE. THE RECALL BEGAN ON JULY 10, 2007. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 07E023000
2007-03-29
CERTAIN CARDONE MASTER CYLINDERS WITH PART NUMBERS 10-2925, 10-2987, 10-2987MZA, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, AND 11-3156, AND WITH DATE CODES LOWER THAN DCA7078 SOLD AS REPLACEMENT EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE SEAL ON MASTER CYLINDER CAN FAIL AND LEAK BRAKE FLUID.
Consequence: LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: CARDONE WILL NOTIFY OWNERS AND OFFER TO REPURCHASE ANY DEFECTIVE MASTER CYLINDERS. THE RECALL BEGAN DURING APRIL 2007. OWNERS CAN CONTACT CARDONE AT 1-800-777-4780.
VEHICLE SPEED CONTROL · 06V441000
2006-11-15 · EA05021
ON CERTAIN PASSENGER VEHICLES, A COMBINATION OF THROTTLE POSITIONING SENSOR IRREGULARITIES, A DIRTY THROTTLE HOUSING, AND/OR INEFFICIENT SOFTWARE CALIBRATION MAY CAUSE A WARNING LAMP TO LIGHT AND THE SUBSEQUENT ONSET OF LIMP HOME MODES.
Consequence: THIS RESULTED IN A HIGH NUMBER OF VEHICLES GOING INTO THE LIMP HOME MODE WITHOUT NEED.
Remedy: DEALERS WILL INSTALL THE CURRENT SOFTWARE UPGRADE ONTO THE INVOLVED VEHICLES. THE RECALL BEGAN ON DECEMBER 29, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN · 04V451000
2004-09-13
ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, UNDER CERTAIN OPERATING CONDITIONS, SOME ELECTRIC COOLING FANS MAY OVERHEAT POTENTIALLY CAUSING HEAT DAMAGE AND, IN RARE INSTANCES, A FIRE IN THE ENGINE COMPARTMENT.
Consequence: A FIRE IN THE ENGINE COMPARTMENT COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE COOLING FAN. THE RECALL BEGAN ON NOVEMBER 29, 2004. CUSTOMERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
EQUIPMENT:OTHER:LABELS · 03V284000
2003-08-01
CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE VEHICLES AND, IN CERTAIN CASES, THE OWNER'S MANUAL ISOFIX INFORMATION IS INCORRECT.
Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
Remedy: OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUCTIONS, AND IN CERTAIN CASES, THE CORRECTED OWNER'S MANUAL MAY BE PROVIDED. IF THE OWNER WANTS TO TAKE THEIR VEHICLE TO A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.
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