Menu

2004 Volvo S60Problems, recalls & complaints

NHTSA has logged 198 owner complaints about the 2004 Volvo S60, most often about the engine and engine cooling. It is covered by 5 safety recalls, and for recall 21V-766 the manufacturer reports only 13% of affected cars repaired.

2004 Volvo S60
26
CarFlaw IndexYear to avoid2.9× the S60 median · #1 of 18 years by complaints
Safety recalls5Lowest repair rate 13%Owner complaints19832 with a crash, fire or injuryTypical failure mileage78kEngine and engine cooling, median miles

Source: NHTSA complaints, recalls, investigations and manufacturer recall reports, through July 8, 2024. Updated daily. Photo: Elise240SX, CC BY-SA 4.0.

Complaints by system

Where the 2004 Volvo S60 has problems

198 complaints grouped by the system owners reported.

Box size = number of complaints naming that system. Darker = larger share. One complaint can name more than one system.
Complaints by system
SystemComplaintsCrash, fire or injury
Engine and engine cooling633
Fuel system, gasoline301
Engine221
Electrical system214
Fuel/propulsion system180
Seats129
Power train121
Vehicle speed control113
Air bags96
17 other systems616

Source: NHTSA Office of Defects Investigation. Complaints are submitted by the public and are not verified by NHTSA.

5 recalls

2004 Volvo S60 recalls and how many were fixed

Each ring shows the share of affected cars repaired, from the manufacturer’s latest quarterly report to NHTSA. Recall repairs are free at authorized dealers.

13%repaired · 2023 Q3

Driver side: inflator module

Recall 21V-766 · Sep 30, 2021 · 259,383 vehicles · 32,487 repaired

Risk. An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Problem, fix and repair progress →

–no report yet

Delivery: fuel pump

Recall 09V-483 · Dec 18, 2009 · 158,733 vehicles

Risk. 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.

Problem, fix and repair progress →

–no report yet

Engine and engine cooling

Recall 07V-226 · Jun 5, 2007 · 32,189 vehicles

Risk. 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.

Problem, fix and repair progress →

Show 1 more recall
–no report yet

Steering: linkages

Recall 04V-029 · Jan 16, 2004 · 29,986 vehicles

Risk. THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.

Problem, fix and repair progress →

Recalls apply to specific cars. To see whether a recall is still open on yours, enter the 17-character VIN at nhtsa.gov/recalls or with Volvo.

Mileage at failure

When do engine and engine cooling problems start?

78kmiles, median

Based on the odometer reading in 55 engine and engine cooling complaints. 80% were reported before 100,000 miles.

median0k50k100k150k200k+
2under 30k miles44under 100k miles11100k miles or more
Best & worst years

2004 vs. every other S60 year

Bars show complaints per model year. Colors show the CarFlaw verdict: complaints weighted for crashes, fires and injuries, adjusted for years on the road and compared with the S60 median. How we score

'01'02'03'04'05'06'07'08'09'11'12'13'14'15'16'17'18'19'20'21'22'23'24'25
  • Avoid
  • Caution
  • Solid
  • Best
  • Not rated
NHTSA crash tests

2004 Volvo S60 safety ratings

2004 Volvo S60 4-DR. w/SAB in NHTSA's New Car Assessment Program. Photos are from NHTSA's crash tests.

2004 Volvo S60 side barrier test, NHTSA
Side barrierNot rated
  • Rollover: 5 stars (9.3% risk)
  • Stability control: Optional
  • Forward collision warning: No
  • Lane departure warning: No
In owners' words

What S60 owners report

Recent engine and engine cooling complaints filed with NHTSA, shortened. Personal details are removed.

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…
Complaint 10679079 · Jan 27, 2015 · 187,000 miles
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…
Complaint 10661751 · Jan 29, 2015
TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH ATTEMPTING TO COME TO A COMPLETE STOP, THE VEHICLE STALLED WITHOUT NOTICE. THE CONTACT MENTIONED ALL LIGHTS ON THE CONTROL PANEL ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO MADE…
Complaint 10609526 · Jul 10, 2014 · 95,000 miles

Own a 2004 S60?

Decode your VIN to see the recalls for your exact car, then confirm open recalls with NHTSA.