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2002 Volvo S60

Owner reports · Recalls · Investigations

More warning signs than most S60 years

Owner complaints for the 2002 Volvo S60 are substantially higher than the model-year median of 20.5.

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When problems were reported

Mileage at the reported incident

145 reports with mileage · 41 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Fuel System, Gasoline. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports3 fire reports7 injury reports

Seats complaints

6 reports
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140,000 miles · Mar 16, 2018
Air BagsElectrical SystemSeats

SERVICE LIGHTS SCROLL IN SPORADIC MOTION FLIPPING THROUGH CONSTANT ALERTS, CHECK ENGINE LIGHT, AIR BAG LIGHT, CONSTANT ELECTRICAL PROBLEMS GOING ON, FUEL DOOR WONT OPEN, BOTH FRONT SEATS HAVE ELECTRICAL PROBLEMS, OBVIOUS BURN THRU ON PASSENGER SIDE INDICATES ITS BEEN OVERHEATED AND DANGEROUS. EVERYTIME I'VE TAKEN IT IN THE SHOP …

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SERVICE LIGHTS SCROLL IN SPORADIC MOTION FLIPPING THROUGH CONSTANT ALERTS, CHECK ENGINE LIGHT, AIR BAG LIGHT, CONSTANT ELECTRICAL PROBLEMS GOING ON, FUEL DOOR WONT OPEN, BOTH FRONT SEATS HAVE ELECTRICAL PROBLEMS, OBVIOUS BURN THRU ON PASSENGER SIDE INDICATES ITS BEEN OVERHEATED AND DANGEROUS. EVERYTIME I'VE TAKEN IT IN THE SHOP THEY SAY THERE ARE NO RECALLS - YET PLENTY OF COMPLAINTS OVER FIRES WITH SEATS. CAN'T USED HEATED SEATS AT ALL. ENGINE SEEMS TO REMAIN INCONSISTENT IN SPEED, DASHBOARD LIGHTS GO COMPLETELY OUT AND THE ELECTRICAL ISSUES AFFECT BACK BRAKE LIGHTS. THE ELECTRICAL ISSUES BOUNCE IN CYCLES TO WHERE NO ONE CAN DETECT THE PROBLEMS. CHECK ENGINE LINE CONTINUES TO HAVE TO BE RESET AND SERVICE LIGHTS CONTINUALLY SEND SCROLLED WARNING TO PULL OVER. ALREADY HAD VEHICLE TOWED AND CAN'T TRUST VEHICLE WILL START. ALWAYS A WIRING ISSUE INVOLVED. THE CAR IS IN THE SHOP NOW AGAIN. 3/16/18 (SAME ISSUES)

NHTSA ODI #11079753

Mileage unknown · Jun 19, 2016
Air BagsElectrical SystemElectronic Stability Control (esc)

"TAKATA RECALL" I JUST GOT MY 2002 VOLVO S60 AS A GIFT AND WAS TOLD THE HEAD GASKET NEEDED TO BE REPLACED. I AM UNABLE TO DO ANYTHING WITH THE VEHICLE DUE TO THE PROBLEMS THAT IT CONSISTS OF BECAUSE OF ALL THE RECALLS ON IT PLEASE HELP ME I NEED A RELIABLE VEHICLE TO TAKE CARE OF MY KIDS AND TO GET BACK AND FORTH TO WORK. I HAV…

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"TAKATA RECALL" I JUST GOT MY 2002 VOLVO S60 AS A GIFT AND WAS TOLD THE HEAD GASKET NEEDED TO BE REPLACED. I AM UNABLE TO DO ANYTHING WITH THE VEHICLE DUE TO THE PROBLEMS THAT IT CONSISTS OF BECAUSE OF ALL THE RECALLS ON IT PLEASE HELP ME I NEED A RELIABLE VEHICLE TO TAKE CARE OF MY KIDS AND TO GET BACK AND FORTH TO WORK. I HAVEN'T HAD THE NAME SWITCHED OVER TO MY NAME YET MY NAME IS [XXX] PHONE NUMBER [XXX] THANK YOU SO MUCH INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10875083

109,000 miles · Feb 13, 2013
SeatsFireInjury

NOTICED A BURNING SMELL WHILE DRIVING, AND SMOKE EMANATING FROM LEFT SIDE OF DRIVER'S SEAT. FELT AROUND AND MY HAND WAS BURNED. PULLED OVER TO FIND THAT THE HEATING ELEMENT INSIDE THE SEAT HAD BURNED THROUGH THE CUSHION AND LEATHER LEAVING A HOLE ON THE SIDE OF THE DRIVER'S SEAT. SEARCHING THE INTERNET, THIS APPEARS TO HAVE ALSO…

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NOTICED A BURNING SMELL WHILE DRIVING, AND SMOKE EMANATING FROM LEFT SIDE OF DRIVER'S SEAT. FELT AROUND AND MY HAND WAS BURNED. PULLED OVER TO FIND THAT THE HEATING ELEMENT INSIDE THE SEAT HAD BURNED THROUGH THE CUSHION AND LEATHER LEAVING A HOLE ON THE SIDE OF THE DRIVER'S SEAT. SEARCHING THE INTERNET, THIS APPEARS TO HAVE ALSO HAPPENED TO OTHER DRIVERS. *TR

NHTSA ODI #10497981

229,000 miles · Jan 9, 2013
Air BagsElectrical SystemEngine And Engine Cooling

WHILE DRIVING IN THE DARK, POWER TO THE ELECTRONICS LISTED BELOW WERE LOST INEVITABLY AND MANY WARNING LIGHTS/MESSAGES APPEARED ON THE DASH (ALSO LISTED BELOW UNDER SYMPTOMS). THERE WERE NO WARNING SIGNS THAT THIS WAS ABOUT TO HAPPEN NOR IS THERE ANY EXPLANATION FOR WHY IT HAPPENED. I WAS DRIVING ON A DARK ROAD AND I LOST COMPLE…

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WHILE DRIVING IN THE DARK, POWER TO THE ELECTRONICS LISTED BELOW WERE LOST INEVITABLY AND MANY WARNING LIGHTS/MESSAGES APPEARED ON THE DASH (ALSO LISTED BELOW UNDER SYMPTOMS). THERE WERE NO WARNING SIGNS THAT THIS WAS ABOUT TO HAPPEN NOR IS THERE ANY EXPLANATION FOR WHY IT HAPPENED. I WAS DRIVING ON A DARK ROAD AND I LOST COMPLETE VISION OF THE ROAD DUE TO HEADLIGHT FAILURE (BOTH LOW AND HIGH BEAMS). THIS SCENARIO IS A COMMON SAFETY ISSUE ASSOCIATED WITH MANY OTHER SIMILAR VOLVO YEARS AND MODELS. I HAD TO STOP THE CAR IMMEDIATELY TO AVOID CRASHING AND CALL SOMEONE TO PICK ME UP. ALL SYMPTOMS FROM THIS "BLACKOUT" DID NOT AND HAVE NOT DISAPPEARED SINCE IT HAPPENED, MAKING THE CAR UNDRIVABLE. THESE SYMPTOMS ARE SUSPECT TO BE THE RESULT OF A CEM FAILURE, WHICH ALSO CONTROLS EMISSIONS. AS STATED PREVIOUSLY, THIS EXACT SCENARIO HAS CAUSED THOUSANDS OF SIMILAR VOLVO YEARS AND MODELS TO BE RECALLED/REPAIRED ON VOLVO'S BEHALF. UNFORTUNATELY, MY VEHICLE MODEL HAS NOT BEEN PLACED UNDER RECALL FOR THIS EXTREMELY, DANGEROUS SAFETY DEFECT. I WOULD LIKE TO SEE ACTION TAKEN AGAINST VOLVO AND REPAIR COSTS COVERED ON THEIR BEHALF. SYMPTOMS: BRAKE FAILURE STOP SAFELY WARNING MESSAGE ENGINE SYSTEM SERVICE REQUIRED WARNING MESSAGE SRS AIRBAG SERVICE URGENT WARNING MESSAGE LOW BEAM HEADLIGHTS NOT WORKING HIGH BEAMS HEADLIGHTS NOT WORKING CHECK ENGINE LIGHT ON ABS LIGHT ON TRACTION CONTROL LIGHT ON ODOMETER NOT WORKING RADIO NOT WORKING POWER SEATS & HEATED SEATS NOT WORKING 12V SOCKETS (FRONT & REAR) NOT WORKING TRIP ODOMETER NOT WORKING CLOCK RESET. *TR

NHTSA ODI #10491975

Mileage unknown · Jan 7, 2006
Seats

WHILE DRIVING IN MY VOLVO S60 THIS PAST WEEK I HAD THE SEAT HEATER ON. I NOTICED IT GOT EXTREMELY HOT, THE SEAT SEEMED MUCH HOTTER THAN IT USUALLY GOT WHEN I DO PUT IT ON, AT FIRST I DIDN'T THINK ANYTHING OF IT SINCE IT HAS BEEN SO COLD I JUST FIGURED "WOW THIS IS WORKING GREAT!" BUT THE NEXT MORNING WHEN GOING OUT TO WORK I N…

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WHILE DRIVING IN MY VOLVO S60 THIS PAST WEEK I HAD THE SEAT HEATER ON. I NOTICED IT GOT EXTREMELY HOT, THE SEAT SEEMED MUCH HOTTER THAN IT USUALLY GOT WHEN I DO PUT IT ON, AT FIRST I DIDN'T THINK ANYTHING OF IT SINCE IT HAS BEEN SO COLD I JUST FIGURED "WOW THIS IS WORKING GREAT!" BUT THE NEXT MORNING WHEN GOING OUT TO WORK I NOTICED A BURNT MARK CIRCLE IN SHAPE ON THE SIDE OF THE SEAT WHEN GETTING INTO MY VOLVO. I WAS UPSET SINCE I DON'T SMOKE AND I AM THE ONLY ONE WHO DRIVES MY CAR. WHEN I WENT TO PUT ON THE HEATER FOR THE SEAT THE SEAT NEVER GOT HOT. I WAS WONDERING IF THEIR IS ANYONE ELSE WHO HAS HAD THIS PROBLEM AND IF THIS CAR HAS A RECALL DUE TO A SAFETY ISSUE. TO ME IT IS OBVIOUS THAT SOMETHING WAS BURNING IN THE HEATING ELEMENT AND BURNT OUT THE SEAT HEATER. IF THERE WAS A RECALL ON THIS I NEVER RECEIVED ANY INFORMATION ABOUT IT. WHAT MADE ME WONDER IF THERE WAS RECALL ON THIS I REMEMBER READING IN THE PAPER ABOUT A WOMEN WHO HAD A FIRE IN HEATED SEAT THIS PAST YEAR. PLEASE GET BACK TO ME REGARDING THIS INFORMATION. THANK YOU, [XXX]. *NM INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10147163

Mileage unknown · Aug 27, 2003
Electrical SystemPower TrainSeats

1) DRIVER'S SEAT SHIFTS REARWARD ON ACCELERATION AND SHIFTS FORWARD ON BRAKING. DEALER HAS ATTEMPTED TO FIX THIS PROBLEM 3 OR MORE TIMES, BUT IT RE-PPEARS SHORTLY AFTER REPAIR. THIS IS A SAFETY ISSUE.*AK 2) VEHICLE DIFFICULT TO SHIFT GEARS (MANUAL TRANSMISSION). GEAR CHANGES ARE VERY 'JERKY', THE VEHICLE CANNOT BE SHIFTED SM…

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1) DRIVER'S SEAT SHIFTS REARWARD ON ACCELERATION AND SHIFTS FORWARD ON BRAKING. DEALER HAS ATTEMPTED TO FIX THIS PROBLEM 3 OR MORE TIMES, BUT IT RE-PPEARS SHORTLY AFTER REPAIR. THIS IS A SAFETY ISSUE.*AK 2) VEHICLE DIFFICULT TO SHIFT GEARS (MANUAL TRANSMISSION). GEAR CHANGES ARE VERY 'JERKY', THE VEHICLE CANNOT BE SHIFTED SMOOTHLY. VOLVO RECOMMENDS LETTING THE CLUTCH SLIP MORE, BUT THIS ONLY MASKS THE PROBLEM. 3) VOLVO ACKNOWLEDGES AN ELECTROMAGNETIC RADIATION PROBLEM WITH THIS VEHICLE, BUT REFUSES TO FIX IT. THIS IS A SAFETY ISSUE.

NHTSA ODI #10036711

Official recalls

8

21V766000 · Air Bags:frontal:driver Side:inflator Module

Sep 30, 2021

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 & remedy

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.

20V681000 · Air Bags:frontal:driver Side:inflator Module

Nov 4, 2020

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 & remedy

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.

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence & remedy

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.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

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 & remedy

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.

07V152000 · Fuel System, Gasoline:delivery:fuel Pump

Apr 5, 2007

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 & remedy

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.

06V441000 · Vehicle Speed Control

Nov 15, 2006

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 & remedy

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.

03V305000 · Equipment:other:labels

Aug 21, 2003

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THE TIRE PRESSURE LABEL IS INCORRECT. THESE VEHICLES DID NOT HAVE THE "MAX LOAD VEHICLE CAPACITY WEIGHT" INFORMATION ON THE LABEL.

Consequence & remedy

Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy: OWNERS WILL BE PROVIDED WITH A CORRECTED LABEL. IF THE OWNER SO DESIRES, A DEALER CAN INSTALL THE LABEL FOR THEM. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

03V284000 · Equipment:other:labels

Aug 1, 2003

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 & remedy

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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA05021 · Throttle Control Malfunction

Opened Dec 6, 2005 · Closed Dec 12, 2006

Status: closed (inferred from source dates) · Vehicle Speed Control

ON NOVEMBER 14, 2006 VOLVO SUBMITTED A DEFECT INFORMATION REPORT TO NHTSA CONCERNING ETM FAILURES IN MODEL YEAR (MY) 1999 THROUGH 2001 VOLVO MODELS (NOT INCLUDING THE S40 AND V40), MY 2002 S60 AND V70 WITH NATURALLY ASPIRATED ENGINES AND MY 2002 V70S.ACCORDING TO VOLVO, ?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.VOLVO FURTHER STATED THAT,THIS RESULTED IN A HIGH NUMBER OF THESE VEHICLES GOING INTO LIMP HOME MODE WITHOUT NEED.?VOLVO INDICATED THAT THIS WAS THE MOST SEVERE CONSEQUENCE OF AN ETM FAULT IN THE SUBJECT VEHICLES.THE RECALL REMEDY IS A SOFTWARE UPGRADE INTRODUCED BY VOLVO ON MARCH 16, 2006 IN A CUSTOMER SATISFACTION PROGRAM.AT THE TIME OF THE NOTIFICATION 161,202 VEHICLES OF THE POPULATION OF 331,301 HAD ALREADY HAD THE SOFTWARE UPLOADED AND WERE THEREFORE NOT INCLUDED IN THE POPULATION COUNT OF THE RECALL. ODI?S ANALYSIS OF COMPLAINTS TO ODI AND VOLVO, VOLVO FIELD REPORTS AND WARRANTY DATA FOUND THAT ETM FAILURE COULD RESULT IN (1) ENGINE STALL; (2) MECHANICAL LIMP MODE; (3) LUNGING FORWARD DURING LOW-SPEED DRIVING MANEUVERS; AND (4) FALTERING DURING HIGH SPEED MERGES OR WHEN CROSSING TRAFFIC.ODI IDENTIFIED 12 CRASHES RELATED TO ETM FAILURE, WITH 6 CAUSED BY LUNGING INCIDENTS, 3 CAUSED BY STALLING INCIDENTS, 2 CAUSED BY MECHANICAL LIMP MODE AND 1 FROM THE FALTERING CONDITION.ODI'S ANALYSIS OF COMPLAINT DATA AND INFORMATION OBTAINED FROM CONSUMER INTERVIEWS IDENTIFIED 1,289 INCIDENTS WITH SAFETY RELATED CONSEQUENCES (389.1 PER 100,000 VEHICLES), INCLUDING 479 INVOLVING ENGINE STALL (144.6 PER 100,000 VEHICLES) AND 729 INVOLVING MECHANICAL LIMP MODE (220.0 PER 100,000 VEHICLES).ODI'S ANALYSIS OF WARRANTY CLAIM NARRATIVE TEXT SHOWS AT LEAST 14,965 WARRANTY CLAIMS WITH CODES INDICATING AN ETM FAULT RESULTING IN VEHICLE OPERATION IN MECHANICAL LIMP MODE (4.5% OF THE SUBJECT VEHICLES). VOLVO?S RECALL ADDRESSES ODI?S SAFETY CONCERNS WITH ETM FAILURES.ODI WILL CONTINUE TO MONITOR THE SUBJECT VEHICLES TO DETERMINE IF ADDITIONAL ACTION IS REQUIRED.THIS ENGINEERING ANALYSIS IS CLOSED.

PE05041 · Throttle Control Malfunction

Opened Jul 26, 2005 · Closed Dec 7, 2005

Status: closed (inferred from source dates) · Vehicle Speed Control

PE05-041 WAS OPENED ON JULY, 26, 2005, BASED ON 136 CONSUMER COMPLAINTS TO ODI ALLEGING THROTTLE CONTROL MALFUNCTIONS IN THE SUBJECT VEHICLES.ODI HAS NOW RECEIVED 591 COMPLAINTS OF ETM FAILURES WHICH ALLEGE SYMPTOMS WITH POTENTIAL SAFETY RELATED CONSEQUENCES.THESE INCLUDE ALLEGATIONS OF ENGINE STALL, VEHICLE SURGING FORWARD WITHOUT ACCELERATOR INPUT, VEHICLE HESITATION UPON ACCELERATION AND SUDDEN AND UNEXPECTED TRANSITION INTO REDUCED PERFORMANCE OPERATION (LIMP MODE).VOLVO SUBMITTED OVER 2,900 COMPLAINTS CONCERNING THE ETM IN THE SUBJECT VEHICLES DURING PE05-041.ODI'S PRELIMINARY ANALYSIS OF A SAMPLE THE VOLVO COMPLAINTS IDENTIFIED APPROXIMATELY 55 PERCENT WITH ONE OR MORE OF THE SYMPTOMS DESCRIBED ABOVE.ODI IS CONTINUING ITS ASSESSMENT OF THE INFORMATION CONTAINED IN THE VOLVO COMPLAINTS. IN NOVEMBER 2005, TO RESOLVE AN INVESTIGATION BY THE CALIFORNIA AIR RESOURCES BOARD, VOLVO ANNOUNCED THAT IT WOULD EXTEND THE WARRANTY COVERAGE TO 10 YEARS / 200,000 MILES FOR THE ETM IN APPROXIMATELY 356,000 MODEL YEAR 1999 THROUGH 2002 PASSENGER CARS SOLD IN THE UNITED STATES AND CANADA.UNDER VOLVO'S POLICY, VEHICLES THAT EXPERIENCE ETM FAILURES WILL RECEIVE A VARIETY OF REPAIRS INCLUDING ETM CLEANING, REPROGRAMMING THE ENGINE CONTROL MODULE AND/OR REPLACEMENT OF THE ETM. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA05-021) TO CONTINUE TO ASSESS THE SAFETY CONSEQUENCES OF ETM FAILURES IN THE SUBJECT VEHICLES.