Most common 2004 Volvo S60 problems
Share of the 198 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Volvo S60 complaints by model year
Best S60 years: 2011, 2025, 2021. Years to avoid: 2012, 2024, 2013, 2015, 2001. Compare all years →
2004 Volvo S60 recalls (5)
Air bags › Frontal › Driver side › Inflator module
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.
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.
Equipment › Electrical › Navigational system(global positioning system)
Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (GPS) units because the batteries on those units May overheat.
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.
Fuel system, gasoline › Delivery › Fuel pump
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,…
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.
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.
Steering › Linkages
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.
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.
What 2004 Volvo S60 owners say
Engine & cooling all 85 →
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.
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. …
Fuel & propulsion system all 55 →
Starting Sunday November 27 my car started dripping gasoline on the floor, on the driver side near the rear wheel. Immediately I took it to Volvo dealer Wynne in Hampton, VA. The service specialist told me there was not any existing recall for that issue and let me go. That night I put under the leak a flat pan. That night I collected one gallon in about 8 hours. I called Volvo cars USA [redacted] explained me the car have been fixed for the campaign #09V483000 in September 14, 2010. I own the car since 2015. I asked her if the recall should be possible to do it again at no cost for me, because it falls under Safety due to the fact the car may get in fire due to the leak of gas. She asked me to go back again to Wynne Volvo dealer and tell to the service specialist that I talked to them and if they wouldn't repair my car I could open a case with Volvo Cars USA. …
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.
Electrical system all 21 →
The contact owns a 2004 Volvo S60. The contact stated that while operating the vehicle, the instrument panel would not illuminate or operate. During the failure, the fuel gauge, speedometer, odometer, and other information was unavailable to the driver. The cause of the failure was not determined. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The failure mileage was 157,000.
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.
2004 Volvo S60 engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 2.4L 5-cyl | 5-speed automatic | FWD | 19 / 28 / 22 |
| 2.4L 5-cyl | 5-speed manual | FWD | 19 / 27 / 22 |
| 2.5L 5-cyl turbo | 5-speed automatic | FWD | 19 / 27 / 22 |
| 2.3L 5-cyl turbo | 5-speed manual | FWD | 18 / 25 / 21 |
| 2.3L 5-cyl turbo | 5-speed automatic | FWD | 18 / 26 / 21 |
| 2.5L 5-cyl turbo | 5-speed automatic | 4WD/AWD | 18 / 25 / 20 |
| 2.5L 5-cyl turbo | 6-speed manual | 4WD/AWD | 16 / 23 / 19 |
EPA ratings. Class: Compact car.
Frequently asked questions
Is the 2004 Volvo S60 a good car?
Based on 198 owner complaints filed with NHTSA, the 2004 S60 rates avoid: 5.7× as many complaints as a typical year of the S60 at the same age. It is one of the S60 years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Volvo S60?
The engine & cooling — 85 complaints, 43% of all complaints for this model year, most often about engine. Next are the fuel & propulsion system (55) and electrical system (21).
How many recalls does the 2004 Volvo S60 have?
There are 5 recalls for the 2004 Volvo S60, the most recent from September 30, 2021 (inflator module). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Volvo S60?
The best years by complaints, compared at the same age, are 2011, 2025 and 2021. Years to avoid or approach with caution: 2012, 2024, 2013, 2015 and 2001. See the full Volvo S60 years comparison.
At what mileage do 2004 Volvo S60 problems happen?
The median mileage reported in complaints is about 79,000 miles; 22% of problems with a recorded mileage started before 50,000 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.