2022 Volvo XC60 Engine Problems

Reporting a manufacturing defect in a 2022 Volvo XC60. The vehicle developed a metallic ticking noise in the timing area, audible at idle. Symptoms strictly match Volvo Technical Journal 36551.9.1 (NHTSA ID: MC-11015995-0001) regarding faulty camshaft seals. The noise disappeared when the oil filler cap was loosened, exactly as described in the TJ. An authorized Volvo dealer confirmed the defect and replaced the camshaft seals per Volvo’s protocol (Work Act No. ЗН-0131107). This repair completely resolved the issue, proving it was a manufacturing fault. The manufacturer refused warranty coverage citing 'salvage title' status, without proving any causal link between the title and this specific engine defect. Failure of timing components poses a significant safety risk, including sudden engine stall or oil leaks during operation. The owner was forced to pay out-of-pocket for the repair of a recognized factory defect. Supporting documents and video evidence are available upon request.

While driving on crowded I40 near Statesville NC, the engine started to stutter and moments later quit entirely. Fortunately we were able to move to the shoulder with only a few seconds to spare. This was very dangerous as we had to move through the right lane in front of speeding semi trucks. The only warning light received was that there was an engine problem, that the car would go into “safe” mode. This was mere seconds before entirely disabling the engine. Had we come to a halt on the highway there would have been a serious accident and injury to ourselves and most likely others. We contacted Volvo, a tow was dispatched and the car was winched on to a flat bed trailer and we were transported to a dealer in Hickory. Later it was confirmed that the Integrated Starter General (ISG) had failed and that power had been interrupted to the hybrid battery. There is a serious problem here and I suspect may impact other “mild hybrid” systems that install integrated alternator/starter motor systems between the engine and transmission.

The contact owns a 2022 Volvo XC60. The contact stated while driving 50 MPH, the vehicle decelerated independently and then stalled. The contact pulled over to the side of the roadway and turned off the vehicle. While attempting to restart the vehicle, the vehicle failed to restart. The vehicle was towed back to residence and then towed to a dealer to be diagnosed. The contact was informed that there was coolant leaking into the engine, and the battery needed to be replaced. The vehicle was not repaired. The VIN was not included in NHTSA Campaign Number: 22V793000 (ENGINE AND ENGINE COOLING). The manufacturer was notified of the failure. The failure mileage was unknown.