2004 volvo s60 purchased the car used in sept 04. On 7/8/24 stranded at 7-11 car wouldn't start. Acting as if there was power loss, AC went off, brake failure light on panel, power windows and locks did not work, temp 105 outside , then driver panel went black., I was scared. Engine wouldn't start. Finally, after waiting 10 minutes...it started running but was sluggish. Radio was on, power door, locks, and windows, did not work. Cut the car off and back on, all power returned, now check engine and air bag trouble on panel. Called volvo dealer next day near my home, they can not see my car til next week tuesday. Can not access engine box, must go to dealer.
The worst 2004 Volvo S60 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Engine85
- Fuel system55
- Electrical21
- Seats12
- Transmission12
- Acceleration11
- Airbags9
- Brakes9
- Steering9
- Tires9
- Lights7
- Body4
- Suspension3
- Locks2
- Seat belts2
- Visibility2
- Driver assistance1
Specific symptoms reported on the 2004 Volvo S60
Stalling 76Check engine light 43Loss of power 16Fuel pump 15Brake failure 11Jerking 9Headlights 8Hesitation 8Power steering loss 6Fire or smoke 5
Recalls 5
Air bags: frontal: driver side: inflator module
- What is wrong
- 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.
- Risk
- 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.
Recall number 21V766000 · Recall details
Equipment: electrical: navigational system(global positioning system)
- What is wrong
- Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (GPS) units because the batteries on those units may overheat.
- Risk
- 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.
Recall number 10V566000 · Recall details
Fuel system, gasoline: delivery: fuel pump
- What is wrong
- 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.
- 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.
- 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.
Recall number 09V483000 · Recall details
Engine and engine cooling
- What is wrong
- 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.
- 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. 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.
Recall number 07V226000 · Recall details
Steering: linkages
- What is wrong
- 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.
- Risk
- 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.
Recall number 04V029000 · Recall details
Technical service bulletins for the 2004 Volvo S60 182
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test
- This is a TJ text only
- This is a Technical Journal
- This is a Technical Journal: Remote connection, BOMGAR application
- Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch...
- This is a Technical Journal: Vehicle/Connectivity report checklist
- Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service
- This is a Technical Journal: 12V Battery Testing Method
- Complimentary upgrade C00009 description.
- Rubber cushion
2004 Volvo S60 fuel economy
Official EPA estimates in miles per gallon (MPGe for electric). Ranges cover trims that share the same engine.
| Engine | Drive | City | Highway | Combined |
|---|---|---|---|---|
| 2.4L 5‑cyl | FWD | 19 | 27-28 | 22 |
| 2.5L 5‑cyl | FWD | 19 | 27 | 22 |
| 2.3L 5‑cyl | FWD | 18 | 25-26 | 21 |
| 2.5L 5‑cyl | 4WD | 16-18 | 23-25 | 19-20 |
What 2004 Volvo S60 owners say
Most recent owner complaints, unedited.
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 [XXX] 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. The service specialist told me I could leave the car for inspection, but I would be responsible for at least $180 to get and estimate, but never said that they would fix it under the safety recall number 09V483000 for vehicles sold or registered in the states with hot climate like Virginia. The recall started in January 15, 2010. It covers the fuel pump that can develop cracks in the fuel pump flange. The technician said the repair they did under the recall was replacing an O-Ring gasket only not the fuel pump. The person I talked to in Service is [XXX] with Title Service Advisor. Phone number [XXX]. I called again today Wednesday November 30, 2022 to Volvo Cars USA they said they can not promise to wave the repair because they need first that I pay $180 for a car diagnostic of the issue. They would probably accept to pay part of the total charge but they would be doing it at good will. I don't have $180 to pay upfront for a safety recall that it didn't last but only 12 years. The Safety recall is valid as long as the car is in service, it doesn't matter if I am or not the first owner. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)
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.
Recall airbags- fuel gauge goes up and down never registers correctly
Driving home from church,, smoke started coming from the drivers seat,from the heated seat. Burned a hole thru the leather . Was able to turn off the switch and put some snow into the golf size hole and pulled the fuse to the elect heat switch. No further damage was noticed .city street. The hole is about 11/2 in below left side beading and closer to front of seat. Leather seat in very good codition and non smoker. Garage keep.
Yes my passenger side seat belt just randomly locked up. My car has never been in any crashes I didn't stop short for it to lock up. I went to put it on and it would only pull half way out and then when it went back it it stuck. It won't come out at all at all now. I can't pass inspection without it working.
My son was in a side impact collision on the passenger side of his 2004 volvo s60. He was in a rural area and either didn't see the oncoming car or missed his stop sign and the oncoming driver was unable to stop. The other driver is uninjured but my son in severely injured with a grade 3 dai head injury. He was wearing his seat belt. The side airbags deployed but not the one in the steering wheel. In an email volvo told me this is how the airbags are designed and that the driver airbags will not deploy on side impact. If that is correct information, this needs to change. The only significant injury my son has is where his head hit the steering wheel, if that airbag had deployed his injuries would have potentially been much less. The airbags are already there, I don't understand why they can't just deploy on any significant impact. I will include pictures.
Tl* the contact owns a 2004 volvo s60. The contact stated while attempting to make a left turn, another vehicle intersected her line causing impact to the front driver's side. The air bags did not deploy. The contact stated that the ABS warning light was illuminated prior to the accident. The contact stated no one sustained injuries or sought medical attention. A police report was filed. The vehicle was not drivable. The vehicle was towed to an impound lot. The vehicle failure had not been diagnosed or repaired by a dealer or independent mechanic. The manufacturer had not been informed of the failure. The failure mileage was approximately 162,000. *ln
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.
Heated seat shorted when turned on on drivers side and burned me while driving.
Compare the 2004 Volvo S60
Other model years
200020012002200320042005200620072008200920112012201320142015201620172018201920202021202220232024
Questions about the 2004 Volvo S60
Is the 2004 Volvo S60 reliable?
Owners have filed 198 complaints about the 2004 Volvo S60, 7.9 times a typical S60 model year. It is one of the years we flag to avoid.
What is the 2004 Volvo S60 year score?
The 2004 Volvo S60 scores 5 out of 100 (poor). The score compares it with the other model years of the Volvo S60: 75 is a typical year, 50 means twice the usual complaints, and serious complaints and recalls lower it.
What is the most common problem with the 2004 Volvo S60?
Engine and cooling, with 85 complaints, typically around 81,500 miles. Next is fuel system (55).
How many recalls does the 2004 Volvo S60 have?
5 recalls, covering air bags, equipment and fuel system, gasoline.
Was there a recall on the 2004 Volvo S60 engine?
Yes, 1 recall: 07V226000. Check your VIN to see if your car still needs the free repair.
What year does the Volvo S60 have bad engine?
The Volvo S60 model years with the most engine complaints are 2004 (85 complaints), 2012 (62 complaints) and 2013 (37 complaints).
Is there a class action lawsuit over the Volvo S60?
Yes. New class action says Volvo's Google-based infotainment screens freeze and take climate and rearview camera with them (November 9, 2026).
What gas mileage does the 2004 Volvo S60 get?
Official estimates for the 2004 Volvo S60 range from 19 to 22 mpg combined. The most efficient version (2.4L 5-cyl, FWD) gets 19 city and 27-28 highway.
VIN decoder
See the problems and recalls for an exact car
Buying a used 2004 Volvo S60?
Check the exact car before you pay: accidents, salvage or flood titles, odometer readings and previous owners.
Check its history