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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

Seats complaints

12 reports
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107,000 miles · Apr 5, 2021
SeatsFire

DRIVING HOME FROM CHURCH,, SMOKE STARTED COMING FROM THE DRIVERS SEAT,FROM THE HEATED SEAT. BURNED A HOLE THRU THE LEATHER . WAS ABLE TO TURN OFF THE SWITCH AND PUT SOME SNOW INTO THE GOLF SIZE HOLE AND PULLED THE FUSE TO THE ELECT HEAT SWITCH. NO FURTHER DAMAGE WAS NOTICED .CITY STREET. THE HOLE IS ABOUT 11/2 IN BELOW LEFT SI…

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DRIVING HOME FROM CHURCH,, SMOKE STARTED COMING FROM THE DRIVERS SEAT,FROM THE HEATED SEAT. BURNED A HOLE THRU THE LEATHER . WAS ABLE TO TURN OFF THE SWITCH AND PUT SOME SNOW INTO THE GOLF SIZE HOLE AND PULLED THE FUSE TO THE ELECT HEAT SWITCH. NO FURTHER DAMAGE WAS NOTICED .CITY STREET. THE HOLE IS ABOUT 11/2 IN BELOW LEFT SIDE BEADING AND CLOSER TO FRONT OF SEAT. LEATHER SEAT IN VERY GOOD CODITION AND NON SMOKER. GARAGE KEEP.

NHTSA ODI #11406424

155,000 miles · Jan 25, 2018
SeatsFireInjury

HEATED SEAT SHORTED WHEN TURNED ON ON DRIVERS SIDE AND BURNED ME WHILE DRIVING.

NHTSA ODI #11064892

107,000 miles · Mar 3, 2015
SeatsFire

TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE THE HEATED DRIVER SIDE SEAT WAS IN THE ON POSITION, A BURNING ODOR STARTED TO EMIT INSIDE THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACTED DISCOVERED A FLAME COMING FROM THE SIDE OF THE DRIVER SEAT. THE CONTACT INDICATED THAT THE FLAME SELF EXTINGUISHED.…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE THE HEATED DRIVER SIDE SEAT WAS IN THE ON POSITION, A BURNING ODOR STARTED TO EMIT INSIDE THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACTED DISCOVERED A FLAME COMING FROM THE SIDE OF THE DRIVER SEAT. THE CONTACT INDICATED THAT THE FLAME SELF EXTINGUISHED. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 107,000. UPDATED 4/7/15*CN

NHTSA ODI #10691802

67,275 miles · Dec 29, 2014
Electrical SystemSeatsFire

DRIVER'S SIDE SEAT STARTED SMOKING WITHIN A FEW SECONDS OF STARTING THE VEHICLE WHILE BACKING OUT OF PARKING PLACE. SEAT HEATER WAS ON. IMMEDIATELY STOPPED AND TURNED OFF SEAT HEATER AND SMOKING STOPPED. QUARTER SIZE HOLE WAS BURNED INTO THE LEATHER SEAT BOTTOM ON THE DRIVER'S SIDE OUTSIDE PANEL. TOOK IT TO DARRELL WALTRIP VOLVO…

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DRIVER'S SIDE SEAT STARTED SMOKING WITHIN A FEW SECONDS OF STARTING THE VEHICLE WHILE BACKING OUT OF PARKING PLACE. SEAT HEATER WAS ON. IMMEDIATELY STOPPED AND TURNED OFF SEAT HEATER AND SMOKING STOPPED. QUARTER SIZE HOLE WAS BURNED INTO THE LEATHER SEAT BOTTOM ON THE DRIVER'S SIDE OUTSIDE PANEL. TOOK IT TO DARRELL WALTRIP VOLVO/SUBARU IN FRANKLIN, TN, AND THEY SAID IT WAS THE SEAT HEATER AND TOOK THE FUSE OUT. SAID IT WASN'T COVERED UNDER WARRANTY AND NO RECALL OUT. HOPE NO ONE HAS THIS PROBLEM DRIVING DOWN THE INTERSTATE. BEST REGARDS AND THANKS FOR ALL YOUR HARD WORK, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10668747

48,200 miles · Mar 1, 2013
SeatsFire

THE DRIVER SEAT OVERHEATED, APPARENTLY FROM A MALFUNCTIONING SEAT WARMER, CAUSING COMBUSTION. THE FIRE BURNED THROUGH THE SEAT PADDING, OUTER LEATHER COVERING, AND THE DRIVER'S CLOTHING. IT BURNED INTO A WALLET IN THE DRIVER'S BACK POCKET, WHICH PROTECTED THE DRIVER FROM A BURN. THE BURN HOLE IN THE SEAT IS ABOUT THE SIZE OF A N…

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THE DRIVER SEAT OVERHEATED, APPARENTLY FROM A MALFUNCTIONING SEAT WARMER, CAUSING COMBUSTION. THE FIRE BURNED THROUGH THE SEAT PADDING, OUTER LEATHER COVERING, AND THE DRIVER'S CLOTHING. IT BURNED INTO A WALLET IN THE DRIVER'S BACK POCKET, WHICH PROTECTED THE DRIVER FROM A BURN. THE BURN HOLE IN THE SEAT IS ABOUT THE SIZE OF A NICKEL. *TR

NHTSA ODI #10500970

300,000 miles · Jan 30, 2013
Seats

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT HE ACTIVATED THE HEATED SEATS AND AFTER A MATTER OF MINUTES, SMOKE BELLOWED FROM THE SIDE OF THE DRIVER'S SEAT. THE SEAT WARMER WAS DEACTIVATED AND THE CONTACT NOTICED THAT A ONE INCH HOLE HAD BEEN BURNED INTO THE SEAT. THE VEHICLE HAD NOT BEEN DIAGNOSED BY A MECHANI…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT HE ACTIVATED THE HEATED SEATS AND AFTER A MATTER OF MINUTES, SMOKE BELLOWED FROM THE SIDE OF THE DRIVER'S SEAT. THE SEAT WARMER WAS DEACTIVATED AND THE CONTACT NOTICED THAT A ONE INCH HOLE HAD BEEN BURNED INTO THE SEAT. THE VEHICLE HAD NOT BEEN DIAGNOSED BY A MECHANIC. THE MANUFACTURER HAD NOT BEEN NOTIFIED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 300,000. UPDATED 2/12/13 *CN

NHTSA ODI #10495231

105,590 miles · Jan 19, 2013
SeatsFire

JUST LEAVING MY GARAGE, WE SMELLED SOMETHING AND IMMEDIATELY SAW SMOKE COMING FROM THE LEFT SIDE OF THE DRIVER SEAT. THE SEAT WARMER WAS ON. WE TURNED THE WARMER OFF AND OPENED THE DOORS. THE ODOR AND SMOKE DISSIPATED BUT THERE IS A 1-1/2" HOLE BURNED IN THE LEATHER. *TR

NHTSA ODI #10493519

140,000 miles · Feb 9, 2012
Electrical SystemSeatsFire

LIKE MANY OTHERS WHO ARE ON VOLVO WEBSITES HAVE REPORTED I TOO HAD A FIRE ON THE DRIVERS SEAT LEFT SIDE DUE TO MY SEAT HEATER. I NOW HAVE A HALF DOLLAR SIZED HOLE IN THE SIDE OF MY SEAT. THE FIRST SIGN OF THIS WAS A SMELL AND THEN A LOT OF SMOKE. LUCKILY I WAS ABLE TO PULL OVER QUICKLY AND HAD A TOWEL HANDY TO SNUFF IT OUT, OTHE…

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LIKE MANY OTHERS WHO ARE ON VOLVO WEBSITES HAVE REPORTED I TOO HAD A FIRE ON THE DRIVERS SEAT LEFT SIDE DUE TO MY SEAT HEATER. I NOW HAVE A HALF DOLLAR SIZED HOLE IN THE SIDE OF MY SEAT. THE FIRST SIGN OF THIS WAS A SMELL AND THEN A LOT OF SMOKE. LUCKILY I WAS ABLE TO PULL OVER QUICKLY AND HAD A TOWEL HANDY TO SNUFF IT OUT, OTHERWISE I WOULD HAVE BURNED HANDS OR OTHER PARTS. I'VE BEEN A LIFELONG VOLVO OWNER, I HAVE TO SAY I'M SURPRISED VOLVO HASN'T AT LEAST WARNED THEIR DEALERS ABOUT THIS PROBLEM. I DID SEE ANOTHER DRIVERS SEAT TOTALLY BLACKENED AND BURNT OUT LAST TIME I TOOK MY CAR IN, WAS AMAZED THAT IT COULD EVEN HAPPEN LET ALONE BE A COMMON OCCURRENCE. NOW AFTER SEARCHING ONLINE THIS IS A PREVALENT PROBLEM. *TR

NHTSA ODI #10447294

Mileage unknown · Mar 24, 2011
SeatsFire

BURNING PASSENGER SEAT IN 2004 VOLVO S60R. WHILE DRIVING I SMELT A HORRIBLE BURNING SMELL AND SEEN SMOKE COMING FROM THE PASSENGER SEAT WHICH EVENTUALLY STARTED A FIRE. I TURNED OFF THE HEATED SEATS AND NOW HAVE A BURN ABOUT AN INCH IN DIAMETER. THIS IS VERY DANGEROUS AND SHOULD BE RECALLED IMMEDIATELY. THIS IS A SERIOUS SAFETY…

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BURNING PASSENGER SEAT IN 2004 VOLVO S60R. WHILE DRIVING I SMELT A HORRIBLE BURNING SMELL AND SEEN SMOKE COMING FROM THE PASSENGER SEAT WHICH EVENTUALLY STARTED A FIRE. I TURNED OFF THE HEATED SEATS AND NOW HAVE A BURN ABOUT AN INCH IN DIAMETER. THIS IS VERY DANGEROUS AND SHOULD BE RECALLED IMMEDIATELY. THIS IS A SERIOUS SAFETY ISSUE THAT NEEDS TO BE ADDRESSED. NOT HAPPY WITH THIS AT ALL! GLAD NO ONE GOT HURT! *TR

NHTSA ODI #10392822

126,597 miles · Dec 19, 2010
SeatsFire

WHILE DRIVING VEHICLE NOTICED VERY STRONG BURNING SMELL. FELT BURNING SENSATION THROUGH SLACK LEG WHILE STILL DRIVING. NOTICED A HOLE HAD BURNED THROUGH LEATHER ON REAR LEFT SIDE OF DRIVERS SEAT. SMOKE WAS PUMPING OUT OF HOLE IN LEATHER (APPX 1/2-INCH ROUND) FROM SEAT PADDING. I IMMEDIATELY TURNED SEAT WARMER OFF AND THE BURNING…

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WHILE DRIVING VEHICLE NOTICED VERY STRONG BURNING SMELL. FELT BURNING SENSATION THROUGH SLACK LEG WHILE STILL DRIVING. NOTICED A HOLE HAD BURNED THROUGH LEATHER ON REAR LEFT SIDE OF DRIVERS SEAT. SMOKE WAS PUMPING OUT OF HOLE IN LEATHER (APPX 1/2-INCH ROUND) FROM SEAT PADDING. I IMMEDIATELY TURNED SEAT WARMER OFF AND THE BURNING STOPPED. AN HOUR LATER, I TURNED SEAT WARMER ON WHILE AUTO WAS RUNNING. SMOKE BEGAN COMING OUT OF SEAT HOLE WITHIN ABOUT 30-45 SECONDS. TURNED OFF SEAT WARMER IMMEDIATELY. BURNING STOPPED. VERY DANGEROUS SITUATION. INSIDE OF AUTO NOW STINKS OF BURNED PLASTIC/FOAM. *TR

NHTSA ODI #10371219

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.