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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

What owners actually said

198 reports
67,275 miles · Dec 29, 2014
Electrical SystemSeatsFire

DRIVER'S SIDE SEAT STARTED SMOKING WITHIN A FEW SECONDS OF STARTING THE VEHICLE WHILE BACKING OUT OF PARKING PLACE. SEAT HEATER WAS ON. IMMEDIATELY STOPPED AND TURNED OFF SEAT HEATER AND SMOKING STOPPED. QUARTER SIZE HOLE WAS BURNED INTO THE LEATHER SEAT BOTTOM ON THE DRIVER'S SIDE OUTSIDE PANEL. TOOK IT TO DARRELL WALTRIP VOLVO…

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DRIVER'S SIDE SEAT STARTED SMOKING WITHIN A FEW SECONDS OF STARTING THE VEHICLE WHILE BACKING OUT OF PARKING PLACE. SEAT HEATER WAS ON. IMMEDIATELY STOPPED AND TURNED OFF SEAT HEATER AND SMOKING STOPPED. QUARTER SIZE HOLE WAS BURNED INTO THE LEATHER SEAT BOTTOM ON THE DRIVER'S SIDE OUTSIDE PANEL. TOOK IT TO DARRELL WALTRIP VOLVO/SUBARU IN FRANKLIN, TN, AND THEY SAID IT WAS THE SEAT HEATER AND TOOK THE FUSE OUT. SAID IT WASN'T COVERED UNDER WARRANTY AND NO RECALL OUT. HOPE NO ONE HAS THIS PROBLEM DRIVING DOWN THE INTERSTATE. BEST REGARDS AND THANKS FOR ALL YOUR HARD WORK, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10668747

97,000 miles · Dec 22, 2014
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE PARKED, THE VEHICLE WAS LEAKING A LARGE AMOUNT OF FUEL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 97,000.

NHTSA ODI #10667635

160,000 miles · Dec 2, 2014
Engine

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING 5 MPH, THE ENGINE STALLED.THE PROBLEM RECURRED NUMEROUS OF TIMES. THE VEHICLE WAS NOT TAKEN TO A DEALER NOR INDEPENDENT MECHANIC. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 160,000…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING 5 MPH, THE ENGINE STALLED.THE PROBLEM RECURRED NUMEROUS OF TIMES. THE VEHICLE WAS NOT TAKEN TO A DEALER NOR INDEPENDENT MECHANIC. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.

NHTSA ODI #10661589

155,000 miles · Nov 10, 2014
Fuel System, Gasoline

MY CAR WAS DYING ON THE HIGHWAY OR ON A REGULAR STREET ROAD. ENDED UP BEING THE FUEL PRESSURE SENSOR WHICH IS ON THE RECALL LIST BUT DIDN'T COME UP FOR MY VIN. I WAS DEALING WITH THIS FOR 6 MONTHS OR SO AND IT WAS VERY DANGEROUS. I DON'T UNDERSTAND WHY MY CAR ISN'T ON THE RECALL LIST. ANY HELP IS APPRECIATED. [XXX] I…

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MY CAR WAS DYING ON THE HIGHWAY OR ON A REGULAR STREET ROAD. ENDED UP BEING THE FUEL PRESSURE SENSOR WHICH IS ON THE RECALL LIST BUT DIDN'T COME UP FOR MY VIN. I WAS DEALING WITH THIS FOR 6 MONTHS OR SO AND IT WAS VERY DANGEROUS. I DON'T UNDERSTAND WHY MY CAR ISN'T ON THE RECALL LIST. ANY HELP IS APPRECIATED. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10654041

130,000 miles · Oct 31, 2014
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE WOULD LOSE POWER AND EXHIBIT A SUDDEN INCREASE IN ENGINE RPMS BEFORE THE VEHICLE ACCELERATED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED INTERMITTENTLY. THE DEALER DIAGNOSED THAT THE FUEL PRESSURE SENSOR N…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE WOULD LOSE POWER AND EXHIBIT A SUDDEN INCREASE IN ENGINE RPMS BEFORE THE VEHICLE ACCELERATED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED INTERMITTENTLY. THE DEALER DIAGNOSED THAT THE FUEL PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS NOTIFIED OF FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ODI #10651726

90,000 miles · Oct 31, 2014
Electrical SystemPower Train

WHILE DRIVING, THE CAR JERKS VIOLENTLY - THE SAME THING HAPPENS WHEN THE CAR IS IDLING (NO JERK, ONLY AN "CLICK" SOUND). IT HAPPENS ANYTIME BUT SEEMS WORSE IN THE SUMMER BUT I THINK IT'S HOT-HEAT RELATED. THE OTHER ISSUES ARE RELATED: -THE INTERIOR LIGHTS USUALLY COME ON -THE INSTRUMENT PANEL GOES COMPLETELY BLA…

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WHILE DRIVING, THE CAR JERKS VIOLENTLY - THE SAME THING HAPPENS WHEN THE CAR IS IDLING (NO JERK, ONLY AN "CLICK" SOUND). IT HAPPENS ANYTIME BUT SEEMS WORSE IN THE SUMMER BUT I THINK IT'S HOT-HEAT RELATED. THE OTHER ISSUES ARE RELATED: -THE INTERIOR LIGHTS USUALLY COME ON -THE INSTRUMENT PANEL GOES COMPLETELY BLANK/LIGHTS GO OFF/NO AVAILABLE EMERGENCY LIGHTS -THE WINDSHIELD WIPERS MAKE ONE WIPE SOMETIMES -THE "REAR PASSENGER DOOR OPEN" WARNING COMES ON -THE "BRAKE FAILURE STOP SAFELY" WARNING COMES ON AND SOMETIMES "CHECK ENGINE" LIGHT COMES ON. NOT ALL OF THESE SYMPTOMS OCCUR EACH TIME. THERE ARE MORE SEVERE AND LESS SEVERE INCIDENTS. *TR

NHTSA ODI #10651699

108,000 miles · Sep 4, 2014
Engine

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED WHILE DRIVING 70 MPH, THE CHECK ENGINE LIGHT ILLUMINATED. THE PROBLEM RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE HAS NOT BEEN REPAIRED. THE MANUFACTURER HA…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED WHILE DRIVING 70 MPH, THE CHECK ENGINE LIGHT ILLUMINATED. THE PROBLEM RECURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE HAS NOT BEEN REPAIRED. THE MANUFACTURER HAS BEEN MADE AWARE OF THE PROBLEM AND STATED THE VIN WAS NOT INCLUDED IN RECALL NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE FAILURE MILEAGE WAS 108,000.

NHTSA ODI #10630871

203,000 miles · Jul 16, 2014
Fuel System, GasolineVehicle Speed Control

LOSS ACCELERATION IN THE VEHICLE ON THE HIGHWAY AT 60 MPH. THE CAR WOULD NOT SPEED UP AND CONTINUE TO SLOW DOWN BUT NEVER CAME TO A FULL STOP. I WAS NOT ABLE TO GO PASS 40 MPH IN THE CAR AND ACCELERATION WAS SLOW. FIRST TIME IT HAPPEN, THE DEALER SAID THROTTLE BODY AND OIL COLLECTION SYSTEM NEEDED TO BE REPLACED. I REPLACED B…

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LOSS ACCELERATION IN THE VEHICLE ON THE HIGHWAY AT 60 MPH. THE CAR WOULD NOT SPEED UP AND CONTINUE TO SLOW DOWN BUT NEVER CAME TO A FULL STOP. I WAS NOT ABLE TO GO PASS 40 MPH IN THE CAR AND ACCELERATION WAS SLOW. FIRST TIME IT HAPPEN, THE DEALER SAID THROTTLE BODY AND OIL COLLECTION SYSTEM NEEDED TO BE REPLACED. I REPLACED BOTH. IT HAPPENS AGAIN, TOOK IT TO A DIFFERENT PERSON, THE MECHANIC SAID FUEL CONTROL NEEDED TO BE REPLACED. I REPLACED THAT. IT HAPPEN THE THIRD TIME AND TOOK IT TO DEALER AND HE INFORMED ME THE SPARK PLUGS. I REPLACED THAT. NOW, THE PROBLEM IS STILL HAPPENING. *TR

NHTSA ODI #10610925

95,000 miles · Jul 10, 2014
Engine And Engine Cooling

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 THE CONTACT AWARE OF RECALL NHTS…

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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 THE CONTACT AWARE OF RECALL NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING) HOWEVER, THE VIN WAS NOT INCLUDED IN THE RECALL. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 95,000.

NHTSA ODI #10609526

160,000 miles · Jun 5, 2014
Electrical SystemFire

CAR WAS IN PARK AND RUNNING WHEN ELECTRICAL WIRES TO THE WINDSHIELD WIPERS CAUGHT FIRE. THE BUNDLE OF WIRES ARE HOUSED IN A RUBBER TUBE. MY UNDERSTANDING IS RUBBER IS QUITE FIRE-RESISTANT. THERE HAVE BEEN 5 RECALLS ON THIS MODEL, TWO WHICH WERE RELATED TO ELECTRICAL FIRES. NEITHER APPLIED TO THIS PARTICULAR CAR FIRE. LOCAL VO…

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CAR WAS IN PARK AND RUNNING WHEN ELECTRICAL WIRES TO THE WINDSHIELD WIPERS CAUGHT FIRE. THE BUNDLE OF WIRES ARE HOUSED IN A RUBBER TUBE. MY UNDERSTANDING IS RUBBER IS QUITE FIRE-RESISTANT. THERE HAVE BEEN 5 RECALLS ON THIS MODEL, TWO WHICH WERE RELATED TO ELECTRICAL FIRES. NEITHER APPLIED TO THIS PARTICULAR CAR FIRE. LOCAL VOLVO DEALERSHIP WANTS NOTHING TO DO WITH THE SITUATION; THEY SEND US TO CORPORATE CUSTOMER SERVICE AND THEY, IN TURN SEND US BACK TO THE LOCAL DEALERSHIP . SERVICE MANAGER SAID HE WAS NOT A KNOWLEDGEABLE FIRE INSPECTOR AND SUGGESTED THAT WE HIRE AN EXPERT IN THAT FIELD. *TR

NHTSA ODI #10596307

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.