Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Volvo S60 owners, lightly cleaned up (personal details are redacted by NHTSA).
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. …
The driver's control door module (ddm) has failed (very common on the S60). This module controls the windows, door locks, rear-view mirrors, and child-safety locks on the rear doors. Now, both rear doors are permanently locked, and can only be opened with the outside door handles. I feel this is a safety issue. A new replacement unit from Volvo will solve this issue, but Volvo dealers charge about $800. A used ddm will not work, due to the software addressing scheme used by Volvo.
Tl* the contact owns a 2002 Volvo S60. While driving various speeds, there was an abnormal fuel odor coming from the vehicle. The contact observed that the fuel pump module was leaking. The contact also observed that the instrument panel did not display the vehicle mileage. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage was 140,000.
Vehicle gauges tend to all go off and all dials go down as if vehicle isn't on. This is a common problem among volvos and this hasn't been recalled. I was driving at least 70 MPH on the highway and this happened to me.
There were four occupants in the vehicle. As we were driving home from the mall, we noticed a brief interruption in the lights and radio. A few miles down the road, there was an electrical failure and the car shut off in the middle of the road, but we were able to get it cranked back up in less than a minute. We drove approximately two more miles and pulled into our driveway and shut the car off. We heard a sound like an alarm, but it was so faint; before we had time to think about it further, the cab began to fill with blackish grey smoke into the backseat area. We all got out quickly and walked to the back of the car. I noticed flames behind the driver side tail light (where the battery is located) and told my husband. He opened the trunk (burning his fingertips), and flames shot up into the air. I immediately called 911 because the flames were high and fast-moving. …
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. …
We purchased a 2002 Volvo S60 1/21/06 at 1:30 pm with 58542 miles on it and 62 miles later at 6:54 pm we were having problems with the accelerator pedal not responding, the engine accelerating wildly and then no control over the engine as it has gone into a limp mode. We shut the car off for 10 minutes and started the car up and it drove normally so we could get home. Upon getting home and shutting the car off, the problems occurred again and the computer dispalyed no codes when plugged into diagnostic equipment. The problem happened again 1/22/06 and we called the used car dealer to have them pick the car up and they took the vehicle to their garage and I was informed 1/23/06 that there is nothing in the computer and the car is running fine right now. …
Electrical panel fails (gas gauge says empty), passenger and rear door locks, fuel door, and trunk opening also fails. Incredibly dangerous as cannot open the doors unless pulling the door lock up manually from inside the car so therefore can't get to children in the backseat without crawling through the front seat and manually unlocking their door. Have no idea how much gas is in the car because gas gauge fails and cannot get fuel door to open consitently making it difficult to refuel. Car alarm went off in the middle of the night and could not open the car doors to turn it off because of electrical failure and therefore battery drained. It is really dangerous to not be able to lock and unlock the car doors. A child could get trapped in the vehicle or someone could get into the car for fear of locking doors and not being able to get them unlocked. …
The vehicle would not start. There was full battery power and the computer stated it was the immobilizer check manual. Several attempts were made and car sat overnight.the Volvo S60 restarted in the morning. The car ran fine for a day and would not start again. Dealership stated that the antenna ring or key chip might be bad. The antenna ring was changed and the car would not start a week later again. The car was taken to dealer ship and placed on scanner. The car function normally for two weeks and did not start again. Several blogs concerning this matter have been set up without any answers for the consumer. The dealerships scanned the vehicle and changed parts and the problem still persists. In my case the dealership stated that it did show a problem. Yet the problem is not fixed. …
VIN: [redacted]. While starting the car the last week the "engine check and service engine " warning lights lit up. I had it checked and found out the etm (electronic throttle module) is faulty. Called Volvo USA and informed them of the problem but they told me my car, which is a turbo, is not part of their recall. If this type of problem is common to 360,000 volvos and warranty extended to 200,00 miles or 10 years why then are they (Volvo) refusing to fix my etm problem. Since my car is experiencing the same etm malfunction, prior to their extended warranty expires, I would like to have my car be part of the Volvo recall before serious consequence happens. So far nothing has been done with the problem. The warning light "engine checks and service engine" continue to lit up uninterrupted whenever the engine is running.
Electrical complaints in other S60 years
Frequently asked questions
How common are electrical problems on the 2002 Volvo S60?
NHTSA has 36 complaints about the electrical system of the 2002 Volvo S60, 19% of the model year's 186 complaints. The component named most often is ignition (4 mentions).
Is there a recall for 2002 Volvo S60 electrical problems?
No. NHTSA lists no electrical system recall for the 2002 Volvo S60, though it has 8 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Volvo S60 electrical problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 21% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.