Summary
The Volvo S60 has 26 recalls spanning 2001 through 2024, with the most serious being a Takata-related driver airbag defect on 2001-2009 models where the inflator can explode during deployment and send metal fragments into the cabin, risking serious injury or death.
The current and recent generation covers a notable cluster of safety issues. On 2019-2024 vehicles, the front passenger airbag may not be properly secured and can deploy incorrectly in a crash, reducing its ability to protect the occupant. The 2023 model year has two separate electrical concerns: a diagnostic error in the brake control module can disable anti-lock brakes, stability control, and traction control simultaneously, and a false warning for the emergency call system can mask a real failure and delay emergency response after a crash. The 2019 model also has a rear suspension toe link with inadequately tightened locking nuts that can detach and cause a sudden, unexpected change in handling while disabling stability control.
The 2016 model year has two issues worth noting: the automatic stop/start system can blow the starter motor fuse and leave the car unable to restart in traffic, and the front passenger seatbelt buckle can separate from its bracket and fail to restrain the occupant in a crash. Door latches on 2011-2017 models can break internally, making a door appear closed while not fully latched, allowing it to swing open while driving. The 2013 model year has a restraint system control unit that can deploy the seatbelt pretensioners or side curtain airbags without cause, startling the driver and blocking forward visibility.
The 2012 model year carries multiple fuel system concerns: an underbody coating applied incorrectly can form rigid deposits that puncture fuel lines and cause a fire, and separately, a fuel line quick connector can detach, stall the engine, and leak fuel near ignition sources. Fuel pump software incompatibility can also cause hesitation or stall on the same year range. The 2011-2012 five-cylinder engine has a low oil pressure sensor that fails to alert the driver, allowing the engine to run until it stalls without warning.
The 2001-2003 model years, specifically those sold or registered in high-humidity southern states, share the Takata airbag concern noted in the lead, with the same metal fragment risk. The 2001 model in Arizona and Nevada has a fuel pump that can leak and create a fire risk under those states' climate conditions.
