The Volvo XC60 D4 engine has a couple of known issues. One problem is with the intake manifold, which can melt and catch fire in certain cars produced between 2014-2019. Volvo has a recall in place for this issue. Another problem is with the exhaust gas recirculation (EGR) system, where the chambers of the EGR cooler don't seal properly, allowing exhaust gases to mix with coolant. This problem can bring the engine management light on and result in an MOT fail. It can also be expensive to fix, with some owners reporting bills of £1,300. However, Volvo has come up with a fix involving a redesigned EGR cooler and a software update, so cars that have had the replacement cooler fitted after mid-2016 should be safe. Volvo hasn't issued a recall for this issue, but it has agreed to replace the affected components fee-free, even on cars outside of warranty. However, some dealers have told customers that their cars wouldn't be covered, so they had to take their case to Volvo Customer Care. It is important to note that Volvo may reduce the level of goodwill offered on cars that haven't been serviced according to the manufacturer schedule.
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