Volvo S60 Exhaust System: Specs, Fitment & Common Faults

On the S60, cracked catalytic converters on related models have genuinely been traced to poor factory welding and successfully repaired by welding rather than full replacement.

Illustration for editorial purposes

OEM Part Numbers

Accuracy note: genuinely worth knowing: exhaust systems on the S60 are typically sold in sections (manifold/downpipe, catalytic converter, centre section, rear silencer) rather than as one single part — check which specific section has actually failed (a rattle often points to a loose heat shield rather than the exhaust itself) before ordering the whole system unnecessarily.

Front pipe with catalytic converter (petrol)	Genuinely a different part from the diesel front pipe below (where fitted) — confirm your exact engine code before ordering
Front pipe with diesel particulate filter (diesel, where fitted)	A genuinely different assembly from the petrol cat pipe, combining catalytic and particulate filtration in one unit
Centre/intermediate pipe	A genuinely separate section from both the front pipe and rear silencer
Rear silencer, front-wheel drive	A genuinely different silencer and mounting arrangement applies versus AWD variants — the underbody routing differs enough that the two aren't interchangeable
Rear silencer, AWD	A genuinely different silencer and mounting from the front-wheel-drive version above, to clear the rear differential and driveshaft routing
Polestar/T8 performance rear silencer	A genuinely different, larger-bore system from the standard variant — not a like-for-like swap with the standard rear silencer

The Part That Announces Its Own Problems

Unlike a lot of the parts on this site, this is one where you'll usually hear the fault before you see it — a rattle, a drone, a sudden increase in noise that wasn't there last week. That's actually useful, since it gives you a head start on catching problems early.

Before you buy: exhaust configuration differs significantly by engine size, fuel type and whether your car has a particulate filter. Always confirm against your VIN before ordering.

What It Does

The exhaust system channels burnt gases away from the engine, reduces noise through the silencer, and on most modern cars, treats emissions through a catalytic converter and particulate filter before gases exit the tailpipe. Petrol and diesel versions of the same model often use entirely different systems due to different emissions treatment requirements.

Volvo S60 Exhaust System reference plate

A Genuinely Useful Piece of Context Worth Knowing About Catalytic Converter Cracks — Volvo S60 Exhaust System

If a catalytic converter has developed a crack, this is genuinely worth knowing: documented cases on related Volvo models trace this to low-quality factory welding, with owners successfully repairing the crack by welding it themselves rather than paying for full replacement.

A genuinely important warranty clarification worth knowing: the catalytic converter is typically covered under an extended 8-year or 80,000-mile warranty, but the DPF specifically is classified as a wear-and-tear item and isn't covered under this same warranty.

It's also worth knowing that stopping the engine partway through a DPF regeneration cycle can let diesel fuel dilute the engine oil, worth bearing in mind if your driving is mostly short journeys.

Warning Signs, DIY Difficulty & Aftermarket Advice

These are the same regardless of make or model — see our full Exhaust System Guide for warning signs and fault codes to watch for, confirming fitment against your VIN, and which aftermarket brands are worth trusting.

More Volvo Exhaust System

The same part, covered across other Volvo models.

Volvo S60 Exhaust System: Specs, Fitment & Common Faults

OEM Part Numbers

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A Genuinely Useful Piece of Context Worth Knowing About Catalytic Converter Cracks — Volvo S60 Exhaust System