NHTSA Complaint #11452418 — 2012 VOLVO S60

My wife and I were driving to BWI airport for a 10:30am flight from Virginia Beach in the Express Lane on I-95N going 75mph when all of a sudden at 8:30am the engine seized and I got a message telling me I would experience "Reduced Engine Performance" as my car puttered to a stop with white smoke pouring out of the exhaust. Prior to this message I had no warnings or messages on my dashboard. I got out of my car to check my oil and it was completely evaporated, so I called AAA. While we are 1 hour into waiting (it is now 9:30am) on the narrow shoulder of two Express Lanes for a tow truck to take our car to a shop at 11:40am and for a Lyft driver to figure out how to get to us, two VDOT employees told us we had to move our car by 11am otherwise the state police will tow us. I managed to call a local tow company who finally arrived by 10:55am, so we had been stranded in an Express Lane watching cars fly by at 85mph for almost 2 and a half hours before we were able to move. After the first shop took a look and told me the engine was damaged and that they couldn't replace it, I had it towed to a Volvo dealership. 5 days and a $375 diagnostic later, they find that the turbocharger has an internal oil leak and that this and the catalytic converter would have to be replaced for $6k. Aside from now being carless 4 hours from the dealership and missing my wife's birthday celebration without refund, I now have a $6,375 bill that I had no way of preventing due to a manufacturing design flaw in 2012 Volvo S60 T5. I SHOULD have been warned of a low oil situation so I could have at least pulled over and properly tended to it. I SHOULD NOT have to be liable for a Volvo design flaw that may involve faulty piston rings that has apparently affected countless others. This incident put both my wife and I in danger on an Express Lane on a very busy highway. Volvo needs to be accountable for this design flaw.