Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Volvo S60 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2003 Volvo S60. While driving at low speeds, the engine stalled and the check engine warning light illuminated intermittently. The failure recurred numerous times. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and stated that the VIN was not included in NHTSA campaign number: 07V226000 (engine and engine cooling). The failure mileage was 162,000. Updated 09/01/2015 updated 10/27/2015
Tl* the contact owns a 2003 Volvo S60. The contact stated that when the ignition was turned to the on position, the check engine warning indicator illuminated continuously. The vehicle was taken to an independent mechanic where it was diagnosed that the air flow, the pressure, and oxygen sensor needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 110,000.
Fuel leak coming from undercarriage passanger right rear seats, near fuel filter, off the top of the gas tank. Noticable smell and huge hazard for safety. What makes it presence detected is smell inside cabin after filling gas tank at fueling stations.
Dash cluster lights and gauges and turn signal indicator shut down and back on intermittently, motor seems to lose power when driving, and rough idle. The dash cluster problem happens while driving and in the park position.
I was traveling on I-65 from louisville, ky to chicago, illinois and encountered sudden loss of power after driving 205 miles at steady freeway speeds. The car (Volvo S60, 2003 model) suddenly lost power and speed from 70 MPH. I pulled over to the shoulder at a speed of 40 MPH and turned off the engine. I waited 10 minutes and then started the engine and reentered the highway and was able to accelerate to 70 MPH. After about 3-5 minutes the same loss of power occurred and the engine turned off and the oil light remained on. I once again pulled off to the shoulder, turned off the vehicle and called for tow assistance. The car was towed to a Volvo dealer in , indiana (napleton auto) and left for 24 hrs. Dealer reported no diagnostic evidence of problem and was unable to replicate the problem on non-highway drive tests. …
Compliant 1: I have a 2003 S60 Volvo. The instrument panel goes dark and all instruments stop working. This includes all gauges, speedometer, RPM, fuel, temp and blinkers. They all go to zero and panel turns black and completely off. The exterior blinkers do still work. When the panel is working I receive various messages such as SRS airbag service urgent, brake failure, and stop immediately no oil pressure. I took the car to my mechanic and he said it's the driver information module which costs $1300 to replace. My mechanic also stated that this is a reoccuring problem in this car. I have done research on the internet and have found that there are many Volvo's of the same make and model in which the same exact problems are occuring. I feel that the manufacturer should be responsible for fixing this problem. It's obvious that it's a recurring problem. …
On 12 dec, 2008, my 2003 Volvo S60 stalled with no warning while traveling on a busy highway at 60 MPH. I pulled to safety (vehicle was in "limp home" mode) and had the vehicle towed to the dealership (park place Volvo). Since the vehicle started right back up and presented no codes, I was told there was nothing wrong and given a bill for $418 (for tow and diagnostic check). Approx. 1 month later, vehicle presented same problem; it stalled, without warning, while driving... Creating a great safety risk for the second time. I had vehicle towed again to same dealership, and since vehicle started right back up with no codes, I was told there was nothing wrong. Dealership could not get vehicle to duplicate problem on either occasion. …
I own a 2003 Volvo S60, 4 dr sedan, purchased from don beyer Volvo in falls church, va, serviced at don beyer Volvo in dulles, va. The car has suddenly stalled in the middle of an intersection twice in the last 2 weeks but would re-start almost immediately. Last night, it stalled going 70 MPH on a major highway with no warning whatsoever. I lost all power immediately and had to maneuver over lanes of traffic to pull over without power steering. Very dangerous situation. Towed to the dealership where they replaced the fuel pressure regulator and said they've had no other complaints of this sort. However, just tonight I saw a news report on channel 8 news in wash dc stating that Volvo is being investigated for claims of this exact type. Did not see any mention of the S60 model so thought I would report my incident to be included in the investigation.
The grief from this car literally began on the way home from the show room, as the seat belts were not functioning. They required four visits to the service department to correct the problem. The issue of the tires being unsafe became apparent when the car was two weeks old, with under 1000 miles on the odometer front & rear bumpers separate from vehicle , with little or no provocation. Tires self destruct at speeds of 2-4 MPH (while parking), if a curb is touched. I'm informed that tires have weak sidewalls & to replace tires (at my expense). Air conditioning required three visits to repair shop & is still not getting the car as cold as it should in hot weather. I should add that I'm also informed that replacement tires will diminish the handling of the car.
I had a similar issue about two years ago and replaced the catalytic converter. Just today (9/25/10), my 2003 Volvo S60 began to irregularly stall while driving. While I'm slowing down, it downshifts by it self, and just dies, and while I'm slowing down, the warning indicators on the dash are not lit, as if nothing is wrong, but when come to a complete stop all the lights on the dash are lit. The check engine light then comes on, it wasn't on before this happened. This can be very dangerous when you are slowing down to turn at an intersection. The car stall, you have no power steering and you are dead in the middle of traffic. This happened no less than 10 time while I was driving today.
Related recalls
Engine and engine cooling
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.
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.
Engine complaints in other S60 years
Frequently asked questions
How common are engine problems on the 2003 Volvo S60?
NHTSA has 21 complaints about the engine & cooling of the 2003 Volvo S60, 18% of the model year's 120 complaints. The component named most often is engine (6 mentions).
Is there a recall for 2003 Volvo S60 engine problems?
Yes — NHTSA recall 07V-226 (engine and engine cooling, Jun 5, 2007). Recall repairs are free at authorized dealers.
At what mileage do 2003 Volvo S60 engine problems start?
Half of the complaints with a recorded mileage happened before about 59,000 miles, and 16% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.