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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.

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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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41,000 miles · Jun 1, 2012
Engine

THE PCV "FLAME TRAP" HAS CLOGGED IN MY 2004 VOLVO S60 WITH ONLY 41,000 MILES AND AS IT TURNS OUT, THIS IS A $1200 JOB. I WOULDN'T BE SO DISMAYED HAD I NOT DISCOVERED THAT THIS IS AN EXTREMELY PREVALENT PROBLEM AND THAT IT IS GUARANTEED TO HAPPEN TO YOUR CAR PRIOR TO 100,000 MILES. THAT THERE IS NEARLY NO AMOUNT OF MAINTENANCE ON…

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THE PCV "FLAME TRAP" HAS CLOGGED IN MY 2004 VOLVO S60 WITH ONLY 41,000 MILES AND AS IT TURNS OUT, THIS IS A $1200 JOB. I WOULDN'T BE SO DISMAYED HAD I NOT DISCOVERED THAT THIS IS AN EXTREMELY PREVALENT PROBLEM AND THAT IT IS GUARANTEED TO HAPPEN TO YOUR CAR PRIOR TO 100,000 MILES. THAT THERE IS NEARLY NO AMOUNT OF MAINTENANCE ONE CAN DO TO PREVENT THIS PROBLEM. THE WORST PART ABOUT THIS PROBLEM IS THAT IF IT'S NOT REPAIRED PROMPTLY, IT WILL LEAD TO OIL BURNING AND THE DAMAGING OF VARIOUS SEALS IN THE ENGINE WHICH WILL LEAD TO CATASTROPHIC ENGINE FAILURE. VOLVO HAS EXTENDED ITS WARRANTY COVERAGE FOR THIS PROBLEM ON ITS S40 MODEL CARS WHICH SHARE THE ENGINES IN THE S60, YET HAS NOT ACKNOWLEDGED THIS TO BE A MAJOR PROBLEM IN ITS S60 MODELS. *TR

NHTSA ODI #10460300

100 miles · May 22, 2012
Electrical SystemEngineSteering

WHEN TURNING A CORNER. I NOTICED THE CHECK ENGINE LIGHT WAS ON. THE THIS HAPPENED A SECOND TIME A WEEK LATER, AND THEN SEVERAL ADDITIONAL TIMES. I TOOK THE CAR TO INDEPENDENT MECHANIC AND HE CHECKED IT OUT BUT COULDN'T DIAGNOSE THE PROBLEM. HE ONLY SPECULATED THAT IT COULD BE THE PVC BOX, BUT THAT THEY WERE NOT SURE IT WOULD FI…

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WHEN TURNING A CORNER. I NOTICED THE CHECK ENGINE LIGHT WAS ON. THE THIS HAPPENED A SECOND TIME A WEEK LATER, AND THEN SEVERAL ADDITIONAL TIMES. I TOOK THE CAR TO INDEPENDENT MECHANIC AND HE CHECKED IT OUT BUT COULDN'T DIAGNOSE THE PROBLEM. HE ONLY SPECULATED THAT IT COULD BE THE PVC BOX, BUT THAT THEY WERE NOT SURE IT WOULD FIX THE PROBLEM. THE CAR HAD APPROXIMATELY 100K AFTER THIS HAPPENED ABOUT EIGHT TIMES IN THE NEXT 3 MONTHS, I TOOK THE CAR TO VOLVO DEALER. THEY CHECKED IT OUT, AND TOLD ME IT MAY BE THE PVC BOX, BUT THEY WERE NOT SURE THIS WOULD FIX THE PROBLEM. I TOOK IT TO ANOTHER MECHANIC AND WHO SAID IT WAS THE CATALYTYIC CONVERTER. THIS PROBLEM HAS BEEN ONGOING FOR A YEAR. I TOOK THE CAR TO ANOTHER MECHANIC AND HE CHANGED THE SPARK PLUGS AND CABIN FILTER. HE TOLD ME TO TAKE THE CAR TO THE VOLVO DEALERSHIP/SERVICE TO HAVE THE COMPUTER RESET. HE SAID, BECAUSE THE CAR LOOSES PRESSURE AND STALLS WHEN YOU MAKE A QUICK TURN. I CALLED VOLVO THEY SAID THIS WOULD FIX THE PROBLEM. I TOOK THE CAR TO VOLVO TO GET AN OIL CHANGE. THEY TOLD ME THE CAR STALLED OUT ON THE MECHANIC 3 TIMES AND THE CHECK ENGIINE LIGHT WAS ON. THEY CHECKED THE CAR ON THE COMPUTER AND TOLD ME THE ENGINE COILS NEEDED REPLACING. THAT WAS THE PROBLEM. I PAID FOR THE ENGINE COILS TO BE REPLACED AND SOME OTHER WORK WHICH TOTALED $1350.00. I PICKED THE CAR UP ON FRIDAY, ON MONDAY, WHILE TURNING A CORNER THE CAR STALLED OUT, NO POWER, NO STEERING, JUST ONBOARD LIGHTS. IT HAPPENED AGAIN ON TUESDAY MORNING. I EXPERIENCED THIS PROBLEM WHEN THE CAR WAS UNDER RECALL. THE DEALERSHIP FIXED IT, BUT IT SEEMS AS THOUGH THIS PROBLEM IS OCCURING AGAIN. THIS IS DANGEROUS AND VOLVO SHOULD BE RESPONSIBLE AND FIX THESE CARS. THERE ARE SOME SERIOUS MECHANICAL/ENGINE PROBLEMS WITH THIS VEHICLE. *TT

NHTSA ODI #10459330

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.