The 2016 S60 is a solid platform hampered by predictable Volvo issues: transmission oil cooler failures, PCV system problems on turbo fours, and aging P3-platform electrical gremlins. The T5/T6 four-cylinders are more problematic than the older five/six-cylinder models.
Transmission Oil Cooler Failure
Common · high severity
Typical onset: 60,000-100,000 mi
Symptoms: Transmission fluid mixing with coolant (strawberry milkshake in expansion tank), Harsh shifting or slipping, Transmission overheating warnings, Coolant loss with no visible leaks
Fix: Replace transmission oil cooler, flush both cooling system and transmission completely, sometimes requires transmission replacement if contamination is severe. 4-6 hours labor for cooler only, 12-18 hours if trans needs replacement.
Symptoms: High oil consumption (1 quart per 1,000 miles or worse), Rough idle and misfires, Check engine light with lean/rich codes, Oil residue in intake tract, Whistling noise from engine bay
Fix: Replace PCV breather box assembly, oil trap, and all associated hoses. Often requires intake manifold removal. 3-5 hours labor. Delay causes turbo and piston ring damage.
Estimated cost: $800-$1,400
Engine Bearing and Piston Failure (2.0L T5/T6)
Occasional · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Rod knock or metallic rattling at idle, Sudden loss of power, Metal shavings in oil, Catastrophic failure without warning in some cases
Fix: Usually requires complete engine rebuild or replacement. Root cause often tied to ignored PCV issues causing carbon buildup and oil starvation. 20-30 hours labor for rebuild, 12-16 hours for used engine swap.
Symptoms: Clunking when shifting from park to drive, Excessive vibration at idle, Shudder during acceleration, Visible sagging or torn rubber on inspection
Fix: Replace transmission mount(s). Upper mount most common failure point. 1.5-2.5 hours labor.
Estimated cost: $350-$650
Fuel Pump Control Module Failure
Occasional · high severity
Symptoms: No-start condition with no fuel pressure, Intermittent stalling while driving, Check engine light with fuel system codes, Cranks but won't fire
Fix: Replace fuel pump control module (located under vehicle near fuel tank). Often misdiagnosed as fuel pump itself. 1.5-2 hours labor.
Estimated cost: $600-$900
Electronic Throttle Body Failure
Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Limp mode (reduced power), Erratic idle speed, Check engine light with throttle position codes, Throttle response lag or surging
Fix: Replace throttle body assembly. Cleaning rarely works long-term on these. Requires VIDA software for proper adaptation. 1.5-2 hours labor.
Estimated cost: $550-$850
Headlight Wiring Harness Corrosion
Occasional · low severity
Typical onset: 80,000+ mi
Symptoms: Intermittent headlight operation, Flickering lights, Bulb-out warnings with good bulbs, Complete headlight failure one side
Fix: Repair or replace corroded connector at headlight assembly. Sometimes requires harness section replacement. 1-2 hours labor per side.
Estimated cost: $250-$500
Owner tips
Change PCV system components preventively at 60k-70k miles on 2.0L turbo engines — this single step prevents thousands in engine damage
Inspect transmission cooler and flush cooling system/trans fluid together at 50k-60k miles even if no symptoms present
Use Volvo-spec oil (VCC RBS0-2AE) and don't extend drain intervals beyond 5k miles on turbo fours
Budget $1,500/year for deferred maintenance items if buying at 80k+ miles
Buy the T5/T6 only if full service records show PCV work was done and transmission was maintained; otherwise stick with the older five-cylinder models or budget heavily for repairs.
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.
Fitment notes: AGM battery required; located in trunk; European flat plate terminal design
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Control Modules — 2016 Volvo S60
Every control module on the 2011-2018 Volvo S60 — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
⚠️ Not separate module; key programming through CEM; all keys must be present
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
Volvo Cars of N.A., LLC (Volvo) is recalling certain 2008-2016 V70 and XC70, 2007-2016 S80, 2011-2018 S60 and V60, 2016-2018 S60 Cross Country, 2014-2020 S60L, 2009-2015 S80L, 2009-2016 XC60 and 2015-2018 V60 Cross Country vehicles. The flexible steel cable that connects the seat belt to the front outboard seating positions may fatigue over time, causing the seat belt to not secure the occupant in the event of a crash.
Consequence: An unsecured occupant has an increased risk of injury in the event of a crash.
Remedy: Volvo will notify owners, and dealers will replace the seat belt anchor cable for both front seats. The recall began December 10, 2020. Owners may contact Volvo customer service at 1-800-458-1552. Volvo's number for this recall is R10029.
LATCHES/LOCKS/LINKAGES:DOORS:LATCH · 19V849000
2019-11-26
Volvo Car of USA LLC (Volvo) is recalling certain 2011-2017 S60, S60I, V60, S60CC and V60CC vehicles. A component within the door latches may break, making the doors difficult to latch and/or leading the driver or a passenger to believe a door is securely closed when, in fact, it is not.
Consequence: A door that is not securely latched could open while the vehicle is in motion, increasing the risk of injury to a vehicle occupant.
Remedy: Volvo will notify owners, and dealers will replace all four door latches, free of charge. The recall began April 9, 2020. Owners may contact Volvo customer service at 1-800-458-1552. Volvo's number for this recall is R89978.
SEAT BELTS:FRONT:BUCKLE ASSEMBLY · 16V798000
2016-11-02
Volvo Car USA LLC (Volvo) is recalling certain model year 2016-2017 XC90, S90, XC60, V60 Cross Country, V60, S60 Cross Country, S60, and S60 Inscription vehicles manufactured February 16, 2015, to August 22, 2016. On the affected vehicles, the front passenger seat belt buckle attaching stud may loosen, allowing the buckle to separate from the seat belt bracket. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 210, "Seat Belt Assembly Anchorages" and number 209, "Seat Belt Assemblies."
Consequence: If the seat belt buckle separates from the bracket, the front seat passenger may not be adequately restrained in the event of a crash, increasing their risk of injury in the event of a crash.
Remedy: Volvo will notify owners, and dealers will inspect the front passenger seat belt buckle stud, replacing the seat belt buckle as needed, free of charge. The recall began January 2017. Owners may contact Volvo customer service at 1-800-458-1552. Volvo's number for this recall is R89708.
ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS · 15V555000
2015-09-02
Volvo Cars of North America, LLC. (Volvo) is recalling certain model year 2016 Volvo S60, V60, V60CC, XC60, XC70, and S80 vehicles manufactured April 8, 2015 to August 19, 2015. In certain driving conditions when using the automatic engine stop/start function, the starter motor fuse may blow, preventing the car from restarting when necessary.
Consequence: If the vehicle is unexpectedly unable to be started in the middle of traffic, such as when stopped at an intersection, there is an increased risk of a crash.
Remedy: Volvo will notify owners, and dealers will replace the existing starter motor fuse with a higher amperage fuse, free of charge. The recall began on October 26, 2015. Owners may contact Volvo customer service at 1-800-458-1552 or by visiting http://volvo.custhelp.com. Volvo's number for this recall is R39574.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2016 Volvo S60 2.0L I4 Turbo and can vary by trim.
🔧 Built by master technician Chris Hackleman · Master Technician · 20+ years.