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2004 Volvo S60

Owner reports · Recalls · Investigations

More warning signs than most S60 years

Owner complaints for the 2004 Volvo S60 are substantially higher than the model-year median of 20.5.

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When problems were reported

Mileage at the reported incident

173 reports with mileage · 25 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 63 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 30 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

12 crash reports12 fire reports8 injury reports

Fuel System, Other complaints

7 reports
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112,000 miles · Jul 9, 2010
Engine And Engine CoolingFuel System, Other

THE ENGINE LIGHT CAME ON IN MY 2004 VOLVO S60. THE CAR WOULD LOOSE ACCELERATION. TOOK IT TO OUR MECHANIC AND HE SAID IT WAS THE FUEL PRESSURE SENSOR AND THAT IT HAD BEEN RECALLED BY VOLVO- RECALL # 07V226000. TOOK IT TO THE DEALER AND THEY SAID THAT THE VIN # OF MY CAR WAS NOT INCLUDED IN THE RECALL. IT WAS THE SAME PART THAT WA…

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THE ENGINE LIGHT CAME ON IN MY 2004 VOLVO S60. THE CAR WOULD LOOSE ACCELERATION. TOOK IT TO OUR MECHANIC AND HE SAID IT WAS THE FUEL PRESSURE SENSOR AND THAT IT HAD BEEN RECALLED BY VOLVO- RECALL # 07V226000. TOOK IT TO THE DEALER AND THEY SAID THAT THE VIN # OF MY CAR WAS NOT INCLUDED IN THE RECALL. IT WAS THE SAME PART THAT WAS RECALLED ON OTHER 2004 S60S. THE COST WAS $450 TO REPAIR. *TR

NHTSA ODI #10342321

600,000 miles · Apr 1, 2010
Engine And Engine CoolingFuel System, Other

FUEL PRESSURE SENSOR FUNCTIONING OUTSIDE OF ITS NORMAL PARAMETERS ECM CODE 2600. THERE IS RECALL ON THE PROBLEM BUT DEALER WILL NOT REPLACE THE SENSOR FREE OF CHARGE. RECALL #07V226000

NHTSA ODI #10323302

52,000 miles · Feb 15, 2010
Fuel System, Other

VOLVO S60, 2004 RECALL LETTER DATED JANUARY 15, 2010. *TR

NHTSA ODI #10310558

Mileage unknown · Nov 9, 2009
Engine And Engine CoolingExterior LightingFuel System, Other

2004 VOLVO S60 REGULARLY SERVICED BY VOLVO. BOUGHT NEW, WELL MAINTAINED, EXC COND, & OIL CHANGED EVER 3000 MILES. ONLY 68K MILES PRESENTLY BUT MANY PROBLEMS SINCE BOUGHT NEW. #1) REPLACING BURNED OUT REAR/FRONT HEADLIGHT BULBS CONSTANTLY. #2) CHECK ENGINE LIGHT CAME ON BEFORE 40K MILES. WASN'T TOO CONCERNED AT FIRST BECAU…

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2004 VOLVO S60 REGULARLY SERVICED BY VOLVO. BOUGHT NEW, WELL MAINTAINED, EXC COND, & OIL CHANGED EVER 3000 MILES. ONLY 68K MILES PRESENTLY BUT MANY PROBLEMS SINCE BOUGHT NEW. #1) REPLACING BURNED OUT REAR/FRONT HEADLIGHT BULBS CONSTANTLY. #2) CHECK ENGINE LIGHT CAME ON BEFORE 40K MILES. WASN'T TOO CONCERNED AT FIRST BECAUSE ONLY ISSUE I SEEMED TO HAVE WAS HESITATION SOMEWHAT WHEN ACCELERATING AFTER BEING PARKED. UNTIL ONE DAY VEH WOULDN'T ACCELERATE BEYOND A ROLL AFTER BEING STOPPED FOR RED LIGHT. A FEW DAYS LATER DRIVING APPROX 50 MPH UPHILL CAR STOPPED ACCELERATING AND STALLED. BOTH TIMES I WAS ABLE TO ROLL TO SIDE OF ROAD, RESTART & MAKE IT HOME. SCARED ME ENOUGH THOUGH TO TAKE TO VOLVO NEXT DAY. FUEL SENSOR GAUGE NEEDED TO BE REPLACED. WHEN I CHECKED IF COVERED UNDER RECALL - FOUND MY CAR WASN'T BASED ON VIN, ANOTHER FAIRLY COSTLY REPAIR. #3 - AC FAN WOULDN'T GO OFF ONE DAY - FAN RUNNING FULL BLAST & CONTROL SWITCH WOULDN'T REGULATE OR WORK. FAN CONTINUED TO RUN EVEN WHEN I TURNED OFF IGNITION. DEAD BATTERY NEXT MORNING NEEDED JUMP START. AC FAN MODULAR BAD - MODULAR REPAIR DONE & THEN FAN SOMEHOW BURNED OUT DUE TO NEW MODULAR WHEN MECHANIC TESTING REPAIR - NOW FAN NEEDED TO BE REPLACED. VERY COSTLY REPAIR ONCE AGAIN. #3 - CHECK ENGINE LIGHT CAME ON. AFTER MONTHS TO SEVERAL MECHANICS, CHECKING OIL, ETC. TOLD LIGHT PROBABLY JUST FAULTY. THEN CHECK OIL LIGHT BLINKS - CAR HAD LESS THAN 1/2 QT OIL & I HAD MAJOR ENGINE DAMAGE. HAD COMPLETE ENGINE REBUILT & VERY EXPENSIVE. ENGINE RUNNING GREAT. NOW 2 MOS LATER & I HEAR A METAL TO METAL NOISE/SOUND WHEN MAKING TURNS - PREFERABLY RIGHT HAND - & COMING FROM RGHT FRONT SIDE OF CAR. MECHANIC CAN'T SEE SAFETY ISSUES WHEN UP ON RACK. HAS NO CLUE. NOISE ANNOYING AND CONCERNING. IT SOUNDS LIKE WHEEL IS GOING TO FALL OFF CAR. I AM SURE IT WILL COST ANOTHER FORTUNE . HOWEVER ONCE REPAIRED - TRADING IN. I LOVED MY CAR...HOWEVER NO LONGER FEEL VEH IS SAFE OR DEPEN. *TR

NHTSA ODI #10291584

45,000 miles · Mar 19, 2009
Fuel System, Other

2004 VOLVO S60 FUEL PRESSURE SENSOR. VOLVO ISSUED A RECALL FOR THIS FOR 2003-2004 MODELS. MY CAR HAD THIS PROBLEM AND ITS SYMPTOMS (CAR STALLING). VOLVO DEALERSHIP SAID MY CAR DID NOT FALL INTO RECALL DUE TO VIN # BREAK. VOLVO CORPORATION NEVER BOTHERED TO RETURN MY CALLS. I FEEL THAT I SHOULD BE REIMBURSED FOR THIS REPAIR …

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2004 VOLVO S60 FUEL PRESSURE SENSOR. VOLVO ISSUED A RECALL FOR THIS FOR 2003-2004 MODELS. MY CAR HAD THIS PROBLEM AND ITS SYMPTOMS (CAR STALLING). VOLVO DEALERSHIP SAID MY CAR DID NOT FALL INTO RECALL DUE TO VIN # BREAK. VOLVO CORPORATION NEVER BOTHERED TO RETURN MY CALLS. I FEEL THAT I SHOULD BE REIMBURSED FOR THIS REPAIR AS IT CLEARLY MEETS THE RECALL DESCRIPTION. *TR

NHTSA ODI #10262478

Mileage unknown · Apr 21, 2008
Fuel System, Other

WHILE FUELING THE VEHICLE, GASOLINE BUBBLES UP AND OUT THROUGH THE FILLER NECK, LEAVING A LARGE PUDDLE OF GASOLINE ON THE GROUND. THIS GENERALLY HAPPENS WHEN THE TANK IS LESS THAN HALF FULL. *TR

NHTSA ODI #10225299

Mileage unknown · Feb 17, 2008
Fuel System, Other

I HAVE HAD THE SAME PROBLEM OF THE CAR STALLING AROUND TURNS AND ON ABRUPT STOPS. IT SEEMED TO FIRST BE RESOLVED BY THE RECALL OF THE PRESSURE SENSOR. RECENTLY THOUGH THE CAR HAS BEEN STALLING SOMETIMES 5 TIMES PER DAY WHEN DOING THE SAME. THE DEALER CLAIMS IT IS A PVC PROBLEM THAT NEEDS TO BE CLEANED AND WANTS TO CHARGE $100…

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I HAVE HAD THE SAME PROBLEM OF THE CAR STALLING AROUND TURNS AND ON ABRUPT STOPS. IT SEEMED TO FIRST BE RESOLVED BY THE RECALL OF THE PRESSURE SENSOR. RECENTLY THOUGH THE CAR HAS BEEN STALLING SOMETIMES 5 TIMES PER DAY WHEN DOING THE SAME. THE DEALER CLAIMS IT IS A PVC PROBLEM THAT NEEDS TO BE CLEANED AND WANTS TO CHARGE $1000 DOLLARS TO DO IT. *TR

NHTSA ODI #10218252

Official recalls

5

21V766000 · Air Bags:frontal:driver Side:inflator Module

Sep 30, 2021

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.

Consequence & remedy

Consequence: 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.

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence & remedy

Consequence: 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.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

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.

Consequence & remedy

Consequence: 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.

07V226000 · Engine And Engine Cooling

Jun 5, 2007

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.

Consequence & remedy

Consequence: 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.

04V029000 · Steering:linkages

Jan 16, 2004

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.

Consequence & remedy

Consequence: 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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.