Summary
The Volvo S80 has 32 recalls spanning the 1999–2016 production run, with the most serious recent issue affecting 2016 models where the automatic stop-start system can blow the starter motor fuse, leaving the engine unable to restart in traffic and raising the risk of a crash.
The 2016 model year is the only year of late production represented in the recall set. Looking back at the 2011–2013 era, two separate issues can cause the engine to stall while driving: a 2011 engine control module calibration that cuts fuel too aggressively, and a transmission software error on 2011–2013 models that prevents proper downshifting during coasting, dropping engine revs to the point of stall. Both conditions remove propulsion unexpectedly. A separate 2012 concern involves the wire harness under the front seats, which can pull loose when the seat is adjusted and cause front and side airbags to deploy incorrectly or not at all in a crash, and can also disable the seatbelt pretensioner.
The 2010 model has a software fault in the central electronic module that can cut the fuel pump signal, potentially stalling the engine. That same year, an intermittent fault in the driver's airbag clockspring connector can disable the airbag system. On 2008–2009 models, a software error in the fan control module can stop the engine cooling fan entirely, leading to coolant overheating and potential engine failure. The 2008 model year also includes a small batch of V8-equipped vehicles where incorrect engine mount bolts can allow the aluminum bracket to crack and the engine to shift.
The 2007 model year has a power steering return hose that can burst under excess pressure, causing sudden loss of steering assist, and a software fault that can make windshield wipers fail to operate or activate on their own. A front seatbelt cable on 2007 models can also weaken and detach in a crash.
Going back further, 2004 models have front control arm studs that can lose tension, leading to separation between the control arm and spindle. The 2001 model year has a fuel system concern in certain warm-climate states where a fuel leak near an ignition source can cause a fire, and a separate issue where rear outboard seatbelt anchor bolts may have been undertightened. The 2005 model has a battery cable that can chafe against the starter solenoid, creating a short circuit that produces under-hood smoke and prevents starting.
The 1999 model year accounts for several recalls of its own: the electric cooling fan can overheat and cause a fire in the engine compartment, front suspension ball joints can develop excessive play and reduce steering control, and a throttle sensor and software combination can cause the vehicle to enter a reduced-power limp mode.
