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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

What owners actually said

198 reports
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

150,000 miles · Dec 1, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 65 MPH, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CONTACT STATED THAT THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO BE DIAGNOSED AT THE DEALER. THE CONTACT WAS INFORMED THAT THE FUEL PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE …

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TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 65 MPH, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE CONTACT STATED THAT THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO BE DIAGNOSED AT THE DEALER. THE CONTACT WAS INFORMED THAT THE FUEL PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA ODI #10807716

170,000 miles · Sep 28, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHEN TURNING THE KEY INTO THE IGNITION SWITCH, THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 0…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHEN TURNING THE KEY INTO THE IGNITION SWITCH, THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 170,000.

NHTSA ODI #10778030

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

181,150 miles · Apr 1, 2015
Fuel/propulsion System

MARCH 2014: I WAS TRAVELLING ON A DIVIDED HIGHWAY AT 55 MPH AND THE CAR STALLED. MECHANIC STATED IT WAS THE FUEL PUMP. MAR 2015 : THIS SAME EVENT OCCURRED AGAIN. *TR

NHTSA ODI #10703247

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

Mileage unknown · Jan 29, 2015
Engine And Engine Cooling

2004 VOLVO S60R, EXPERIENCE TOTAL ENGINE SHUTDOWN AT APPROXIMATELY 30 MPH THE VEHICLE JUST QUIT RUNNING. CW A DIAGNOSTIC INVESTIGATION BY THE DEALER, CONFIRMED THE FUEL PRESSURE SENSOR WAS AT FAULT. THE SENSOR WAS REPLACED AT A COST OF $ 420.69. THE CONSUMER INQUIRED ABOUT A RECALL. HOWEVER, HE WAS INFORMED HIS VEHICLE WAS NOT…

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2004 VOLVO S60R, EXPERIENCE TOTAL ENGINE SHUTDOWN AT APPROXIMATELY 30 MPH THE VEHICLE JUST QUIT RUNNING. CW A DIAGNOSTIC INVESTIGATION BY THE DEALER, CONFIRMED THE FUEL PRESSURE SENSOR WAS AT FAULT. THE SENSOR WAS REPLACED AT A COST OF $ 420.69. THE CONSUMER INQUIRED ABOUT A RECALL. HOWEVER, HE WAS INFORMED HIS VEHICLE WAS NOT INCLUDED IN RECALL # 07V226000. *JB

NHTSA ODI #10661751

187,000 miles · Jan 27, 2015
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THE CHECK ENGINE LIGHT ILLUMINATED AND THE ENGINE SEIZED. THE FAILURE HAD RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE CONTACT STATED THAT THE VEHICLE WAS EXHIBITING THE SAME FAILURES AS LISTED IN RE…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THE CHECK ENGINE LIGHT ILLUMINATED AND THE ENGINE SEIZED. THE FAILURE HAD RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE CONTACT STATED THAT THE VEHICLE WAS EXHIBITING THE SAME FAILURES AS LISTED IN RECALL NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 187,000.

NHTSA ODI #10679079

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

Mileage unknown · Jan 7, 2015
Steering

I AM WRITING ABOUT WHAT MAY BE DESIGN FLAW WITH THE VOLVO S60R THAT HAS ME VERY CONCERNED. MY FRONT TIRES RUB ON THE BODY IN THE WHEEL WELL WHEN I TURN SHARPLY INTO A PARKING SPACE. I DON'T THINK IT SHOULD DO THAT BUT I'VE BEEN TOLD IT'S "NORMAL" AND THE CAR "SETTLES" AS IT GETS OLDER. SEVERAL OTHER VOLVO S60 OWNERS HAVE THIS SA…

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I AM WRITING ABOUT WHAT MAY BE DESIGN FLAW WITH THE VOLVO S60R THAT HAS ME VERY CONCERNED. MY FRONT TIRES RUB ON THE BODY IN THE WHEEL WELL WHEN I TURN SHARPLY INTO A PARKING SPACE. I DON'T THINK IT SHOULD DO THAT BUT I'VE BEEN TOLD IT'S "NORMAL" AND THE CAR "SETTLES" AS IT GETS OLDER. SEVERAL OTHER VOLVO S60 OWNERS HAVE THIS SAME PROBLEM WHERE THE TIRES RUB ON THE BODY. PLEASE LOOK INTO THIS. I BELIEVE IT WILL CAUSE SERIOUS CONSEQUENCES IN AN EMERGENCY SITUATION AND IT'S WEARING DOWN THE EDGE OF THE TIRES PREMATURELY, WHICH MAY ALSO BE DANGEROUS.

NHTSA ODI #10681259

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.