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 2004 Volvo S60 owners, lightly cleaned up (personal details are redacted by NHTSA).
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. …
Car is Volvo S60 2004 trim 2.4 4 door sedan FWD has 90317 miles on it. From last few weeks when I am driving vehicle it starts losing power and a warning come try slow down or shift up and my check engine light started blinking. This happened 4 times in last 1 week as the result I need to pull my car to safe place and restart that and then it runs better. This has really put me in danger to myself and other people on road. I am scare of driving the car in multiple lane roads in other lanes. I am now driving it on right lane only so that keep myself and other people safe for quick pull over if needed. Check engine gives me code p0171 and p0300. I went on line and followed advice and changed spark plugs, ignition coils and also oxygen sensor but no difference. Still car did same thing when I was driving with my family. …
Tl* the contact owns a 2004 Volvo S60. The contact was driving approximately 30 MPH when the vehicle abnormally accelerated until crashing. There were no injuries. The vehicle was towed to an authorized dealer but the failure was not diagnosed. The vehicle was repaired for the body damages. The failure and current mileage was 92,058. Updated 05/26/11 the consumer stated as she made a turn, the vehicle took off at a very high speed. The vehicle went form side to side as she tried very hard to brake and steer away from the incline on the right. This action continued for about 0.3 miles, before the vehicle air lifted and the right passenger side between the rear door and rear quarter panel hit the guardrail. The vehicle then bounced off the guardrail, crossed the street, jumped the gutter and landed on its wheels in a nearby field, where it came to a stop. …
Tl* the contact owns a 2004 Volvo S60. The contact stated that while driving at approximately 40 MPH, the check engine warning indicator illuminated. The engine started to hesitate and stalled. The contact coasted to the side of the road and waited for approximately three minutes and restarted the vehicle. The contact drove the vehicle to m.p.l. Automotive laconia new hampshire (independent mechanic). The vehicle was diagnosed with a fuel rail pressure sensor needing replacement and also advised the contact of NHTSA campaign number: 07V226000 (engine and engine coolant). The contact called lovering Volvo meredith new hampshire was advised that the VIN was part of the recall. The vehicle was not repaired as of yet. The approximate failure mileage was 158,000.
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.
Tl 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.
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.
Tl* the contact owns a 2004 Volvo S60. While driving at various speeds, the vehicle stalled and the check engine light illuminated. The contact coasted the vehicle to the side of the road, restarted the vehicle, and resumed driving. The failure recurred numerous times. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 155,000.
I was leaving ucla parking garage (I'm an rn there) when I put my Volvo 2004 S60 into gear and it took off backwards like a rocket, car was thrown into a concrete post far away from where I began. I immediately put car in park since I thought I'd get out and see what on earth happened, but it then lunged forward by itself and took off without stopping!!! Thank god it was 6 pm and not an hour earlier when many staff would have been in garage, I'd have run them over! I also turned off ignition with key, nothing helped!! It kept going along with a mind of its own at approx 15 MPH making a growling whirring sound. I was able to steer car and avoid other vehicles but eventually had to make serious decision to purposely crash into another concrete massive post which I did and the "possessed beast". Finally came to a halt with fluid pouring out all over,. …
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 2004 Volvo S60?
NHTSA has 85 complaints about the engine & cooling of the 2004 Volvo S60, 43% of the model year's 198 complaints. The component named most often is engine (9 mentions).
Is there a recall for 2004 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 2004 Volvo S60 engine problems start?
Half of the complaints with a recorded mileage happened before about 82,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 1 fire and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
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.