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2004 Volvo S60

Owner reports · Recalls · Investigations

More warning signs than most S60 years

Owner complaints for the 2004 Volvo S60 are substantially higher than the model-year median of 20.5.

About this comparison →

When problems were reported

Mileage at the reported incident

173 reports with mileage · 25 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 63 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 30 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

12 crash reports12 fire reports8 injury reports

Engine complaints

22 reports
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Mileage unknown · Jul 8, 2024
Air BagsElectrical SystemEngine

2004 VOLVO S60 PURCHASED THE CAR USED IN SEPT 04. On 7/8/24 STRANDED AT 7-11 CAR WOULDN'T START. ACTING AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 OUTSIDE , THEN DRIVER PANEL WENT BLACK., I WAS SCARED. ENGINE WOULDN'T START. FINALLY, AFTER WAITING 10 MIN…

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2004 VOLVO S60 PURCHASED THE CAR USED IN SEPT 04. On 7/8/24 STRANDED AT 7-11 CAR WOULDN'T START. ACTING AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 OUTSIDE , THEN DRIVER PANEL WENT BLACK., I WAS SCARED. ENGINE WOULDN'T START. FINALLY, AFTER WAITING 10 MINUTES...IT STARTED RUNNING BUT WAS SLUGGISH. RADIO WAS ON, POWER DOOR, LOCKS, AND WINDOWS, DID NOT WORK. CUT THE CAR OFF AND BACK ON, ALL POWER RETURNED, NOW CHECK ENGINE AND AIR BAG TROUBLE ON PANEL. CALLED VOLVO DEALER NEXT DAY NEAR MY HOME, THEY CAN NOT SEE MY CAR TIL NEXT WEEK TUESDAY. CAN NOT ACCESS ENGINE BOX, MUST GO TO DEALER.

NHTSA ODI #11600289

30,000 miles · Nov 1, 2018
EngineFire

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE STATIONARY, THE ENGINE CAUGHT FIRE. THE CONTACT STATED THAT SMOKE ENTERED INTO THE CABIN OF THE VEHICLE. THE CONTACT EXITED THE VEHICLE AND OPENED THE HOOD, AND THE ENGINE WAS SURROUNDED BY FLAMES. A POLICE OR FIRE DEPARTMENT REPORT WAS NOT FILED. AN INDEPENDEN…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE STATIONARY, THE ENGINE CAUGHT FIRE. THE CONTACT STATED THAT SMOKE ENTERED INTO THE CABIN OF THE VEHICLE. THE CONTACT EXITED THE VEHICLE AND OPENED THE HOOD, AND THE ENGINE WAS SURROUNDED BY FLAMES. A POLICE OR FIRE DEPARTMENT REPORT WAS NOT FILED. AN INDEPENDENT MECHANIC EXTINGUISHED THE FIRE. THERE WERE NO INJURIES SUSTAINED. A DEALER WAS NOT MADE AWARE OF THE FIRE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FIRE. THE FAILURE MILEAGE WAS APPROXIMATELY 30,000.

NHTSA ODI #11144780

90,112 miles · Nov 3, 2017
Engine

CAR IS VOLVO S60 2004 TRIM 2.4 4 DOOR SEDAN FWD HAS 90317 MILES ON IT. FROM LAST FEW WEEKS WHEN I AM DRIVING VEHICLE IT STARTS LOSING POWER AND A WARNING COME TRY SLOW DOWN OR SHIFT UP AND MY CHECK ENGINE LIGHT STARTED BLINKING. THIS HAPPENED 4 TIMES IN LAST 1 WEEK AS THE RESULT I NEED TO PULL MY CAR TO SAFE PLACE AND RESTAR…

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CAR IS VOLVO S60 2004 TRIM 2.4 4 DOOR SEDAN FWD HAS 90317 MILES ON IT. FROM LAST FEW WEEKS WHEN I AM DRIVING VEHICLE IT STARTS LOSING POWER AND A WARNING COME TRY SLOW DOWN OR SHIFT UP AND MY CHECK ENGINE LIGHT STARTED BLINKING. THIS HAPPENED 4 TIMES IN LAST 1 WEEK AS THE RESULT I NEED TO PULL MY CAR TO SAFE PLACE AND RESTART THAT AND THEN IT RUNS BETTER. THIS HAS REALLY PUT ME IN DANGER TO MYSELF AND OTHER PEOPLE ON ROAD. I AM SCARE OF DRIVING THE CAR IN MULTIPLE LANE ROADS IN OTHER LANES. I AM NOW DRIVING IT ON RIGHT LANE ONLY SO THAT KEEP MYSELF AND OTHER PEOPLE SAFE FOR QUICK PULL OVER IF NEEDED. CHECK ENGINE GIVES ME CODE P0171 AND P0300. I WENT ON LINE AND FOLLOWED ADVICE AND CHANGED SPARK PLUGS, IGNITION COILS AND ALSO OXYGEN SENSOR BUT NO DIFFERENCE. STILL CAR DID SAME THING WHEN I WAS DRIVING WITH MY FAMILY. I WENT ON LINE AND SAW THAT MANY PEOPLE HAVE THAT ISSUE WITH VOLVO S60 OF THIS YEAR AND MODEL AND STRUGGLING. I THINK THIS IS SOME VOLVO S 60 2004 MODEL RECALL ISSUE AS IT IS CREATING ACCIDENTAL HAZARD TO THE OWNER OF THE CAR AND THE OTHER TRAFFIC. DR TAKYAR

NHTSA ODI #11042866

Mileage unknown · Oct 17, 2017
EngineFuel/propulsion SystemSteering

IN STOP AND GO TRAFFIC, MY FOOT WAS ON THE BRAKE TO SLOW DOWN. I TOOK MY FOOT OFF THE BRAKE AND STEPPED ON THE ACCELERATOR AS TRAFFIC MOVED AGAIN, THERE WAS NO RESPONSE TO MY FOOT ON THE GAS PEDAL. THE FUEL TANK, WHICH I HAD JUST FILLED 10 MILES BEFORE, SHOWED AS EMPTY ON THE FUEL GAGE. I WAS VERY, VERY SLOWLY ROLLING FORWARD WI…

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IN STOP AND GO TRAFFIC, MY FOOT WAS ON THE BRAKE TO SLOW DOWN. I TOOK MY FOOT OFF THE BRAKE AND STEPPED ON THE ACCELERATOR AS TRAFFIC MOVED AGAIN, THERE WAS NO RESPONSE TO MY FOOT ON THE GAS PEDAL. THE FUEL TANK, WHICH I HAD JUST FILLED 10 MILES BEFORE, SHOWED AS EMPTY ON THE FUEL GAGE. I WAS VERY, VERY SLOWLY ROLLING FORWARD WITH RESIDUAL MOMENTUM AND MY STEERING WASN'T WORKING. THERE WAS JUST ENOUGH PLAY IN THE WHEEL AND FORWARD MOMENTUM TO AIM AND ARRIVE AT THE SHOULDER OF THE HIGHWAY. THIS WAS ON RTE 156 IN MONTEREY COUNTY, CALIFORNIA, WHERE VERY DANGEROUS ACCIDENTS HAPPEN ALL THE TIME. CAR HAD TO BE TOWED AND THE DEALERSHIP HAS BEEN UNABLE TO REPLICATE FAILURE. IT WAS OUTRAGEOUSLY DANGEROUS AND I WAS ALONE WITH MY 11-YEAR-OLD CHILD. SO FRIGHTENING!!!

NHTSA ODI #11034151

158,000 miles · Jun 28, 2017
Engine

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 40 MPH, THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE ENGINE STARTED TO HESITATE AND STALLED. THE CONTACT COASTED TO THE SIDE OF THE ROAD AND WAITED FOR APPROXIMATELY THREE MINUTES AND RESTARTED THE VEHICLE. THE CONTACT DROVE TH…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 40 MPH, THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE ENGINE STARTED TO HESITATE AND STALLED. THE CONTACT COASTED TO THE SIDE OF THE ROAD AND WAITED FOR APPROXIMATELY THREE MINUTES AND RESTARTED THE VEHICLE. THE CONTACT DROVE THE VEHICLE TO M.P.L. AUTOMOTIVE LACONIA NEW HAMPSHIRE (INDEPENDENT MECHANIC). THE VEHICLE WAS DIAGNOSED WITH A FUEL RAIL PRESSURE SENSOR NEEDING REPLACEMENT AND ALSO ADVISED THE CONTACT OF NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLANT). THE CONTACT CALLED LOVERING VOLVO MEREDITH NEW HAMPSHIRE WAS ADVISED THAT THE VIN WAS PART OF THE RECALL. THE VEHICLE WAS NOT REPAIRED AS OF YET. THE APPROXIMATE FAILURE MILEAGE WAS 158,000.

NHTSA ODI #11001876

155,000 miles · Jul 5, 2016
Electrical SystemEngine

TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED AND THE CHECK ENGINE LIGHT ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, RESTARTED THE VEHICLE, AND RESUMED DRIVING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER …

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TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED AND THE CHECK ENGINE LIGHT ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, RESTARTED THE VEHICLE, AND RESUMED DRIVING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 155,000.

NHTSA ODI #10882802

Mileage unknown · Jun 18, 2016
EngineFuel/propulsion System

CAR STALLED WHILST BREAKING

NHTSA ODI #10875002

140,000 miles · Dec 7, 2015
EngineFuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL RAI…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL RAIL PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.

NHTSA ODI #10808882

111,000 miles · Aug 12, 2015
Engine

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE STALLED ON MULTIPLE OCCASIONS WHILE DRIVING. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE VEH…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE STALLED ON MULTIPLE OCCASIONS WHILE DRIVING. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 111,000.

NHTSA ODI #10748225

100,000 miles · Jan 21, 2015
EngineService BrakesSteering

THE 2.4L 2004 VOLVO S60 EXPERIENCES ERRATIC BEHAVIOR AND ENGINE FAILURE WHEN OPERATING MULTIPLE CONCURRENT ELECTRICAL SYSTEMS. WHEN THESE SYSTEMS (OPERATED WITHIN SPECIFIED GUIDELINES) ARE USED CONCURRENTLY THEY CAUSE THE FOLLOWING CONDITIONS: ENGINE FAILURE, LOSS OF POWER STEERING, LOSS OF BRAKES. THE FOLLOWING IS A LIST OF…

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THE 2.4L 2004 VOLVO S60 EXPERIENCES ERRATIC BEHAVIOR AND ENGINE FAILURE WHEN OPERATING MULTIPLE CONCURRENT ELECTRICAL SYSTEMS. WHEN THESE SYSTEMS (OPERATED WITHIN SPECIFIED GUIDELINES) ARE USED CONCURRENTLY THEY CAUSE THE FOLLOWING CONDITIONS: ENGINE FAILURE, LOSS OF POWER STEERING, LOSS OF BRAKES. THE FOLLOWING IS A LIST OF ELECTRICAL CHANNELS THAT HAVE BEEN USED TO TRIGGER THE ENGINE FAILURE: BRAKES, INDICATOR LIGHTS (RIGHT OR LEFT) HEATED SEATS (X2) FRONT WINDSHIELD DEFROST MULTIPLE S60 MODEL OWNERS HAVE REPORTED HAVING EXPERIENCED THIS SAME ENGINE FAILURE WHICH CANNOT BE DETECTED BY THE MANUFACTURES DIAGNOSTICS TEST. WHEN TESTED THE BATTERY, ALTERNATOR AND COMPUTER ALL PRESENT POSITIVE READ-OUTS. HTTP://REPAIRPAL.COM/REPLACED-MAP-SENOR-AND-MAF-AIRFLOW-ENGINE-LIGHT-BACK-ON-HESITATE-STILL-CUT-OFF-321 HTTP://COMMUNITY.CARTALK.COM/DISCUSSION/2290017/VOLVO-S60-ENGINE-CUTS-OFF-WHILE-TURNING HTTPS://ANSWERS.YAHOO.COM/QUESTION/INDEX?QID=20110502120739AA0TJSR THIS IS A SERIOUS CONDITION THAT COULD RESULT IN A COLLISION OR EVEN DEATH. A RECALL ON THIS MODEL IS BEING IMMEDIATELY REQUESTED. THANK YOU, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10677090

Official recalls

5

21V766000 · Air Bags:frontal:driver Side:inflator Module

Sep 30, 2021

Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Remedy: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence & remedy

Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.

Consequence & remedy

Consequence: IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

07V226000 · Engine And Engine Cooling

Jun 5, 2007

ON CERTAIN PASSENGER VEHICLES, THE FUEL PRESSURE SENSOR LOCATED ON THE LEFT END OF THE FUEL RAIL MAY, AT TIMES, TRANSMIT INCORRECT SIGNAL REGARDING THE FUEL PRESSURE TO THE ENGINE CONTROL MODULE. IF THE SIGNAL IS OUTSIDE OF THE PRE-PROGRAMMED ALLOWABLE LIMITS, A DIAGNOSTIC TROUBLE CODE MAY BE SET AND THE CHECK ENGINE LIGHT WILL COME ON. THE SOLDERED JOINTS ON THE CIRCUIT BOARD OF THE FUEL PRESSURE SENSOR MAY CRACK DUE TO TEMPERATURE CHANGES AND EXCESSIVE VIBRATIONS.

Consequence & remedy

Consequence: MISFIRE MAY OCCUR DURING DRIVING THAT, IN TURN, WILL REDUCE THE ENGINE TORQUE AND IN THE WORST CASE SCENARIO, THE ENGINE MAY STALL WITHOUT WARNING. IN CERTAIN TRAFFIC SITUATIONS THIS COULD CAUSE AN UNSAFE SITUATION AND POSSIBLY A CRASH.

Remedy: DEALERS WILL REPLACE THE FUEL PRESSURE SENSOR FREE OF CHARGE. THE RECALL BEGAN ON JUNE 29, 2007. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

04V029000 · Steering:linkages

Jan 16, 2004

ON CERTAIN PASSENGER VEHICLES, THE FRONT CONTROL ARMS MAY NOT HAVE BEEN MANUFACTURED CORRECTLY AND, AS A RESULT, THE STUD AND NUT THAT SECURE THE ARM TO THE SPINDLE MAY LOSE THEIR INITIAL AXIAL TENSION. UNDER CERTAIN DRIVING CONDITIONS, THE STEERING MAY BECOME LESS RESPONSIVE AND THE DRIVER MAY EXPERIENCE STEERING WHEEL PLAY.

Consequence & remedy

Consequence: THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A NEW TYPE OF NUT. OWNER NOTIFICATION BEGAN ON FEBRUARY 16, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.