Skip to content
Volvo S60Model year report

2004 Volvo S60 Problems

Complaints
198filed with NHTSA
Median mileage
79,122miles, 172 complaints with mileage
Recalls
5campaigns on record
Trend
FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
22 mpgcombined, 2.4L 5-cyl FWD · 19 city / 28 hwy

Sources: NHTSA records for the 2004 Volvo S60 (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error

What owners report

Owners of the 2004 Volvo S60 most often describe the engine cutting out while driving, frequently traced by shops to a fuel pressure sensor, and many say the dealer told them their VIN was not included in the related fuel pressure recall. Cooling system and fuel system complaints are the two largest groups in the sample. Complaints also mention fuel pump failures, electrical and instrument panel faults, seat heater scorching, and airbags that did not deploy in a crash.

  1. Fuel system

    Engine stalls or loses power while driving (fuel pressure

    • 66 complaints (33%)
    • median 80,400 mi at 7.1 yrs old (62 state mileage)
    • 2 mention a crash, fire or injury
    • filed 2007–2017

    Complaints describe the engine shutting down or losing power without warning at speeds from a walking pace to highway speed, sometimes with the check engine light on and sometimes with the car restarting normally afterward. Several owners say an independent mechanic or the dealer identified the fuel pressure or fuel rail pressure sensor, and some report the dealer replaced it. Many say they asked about recall 07V226000 and were told their VIN was not covered, while a few report the same symptoms returning after the recall work was done. Reported across a wide range, from about 35,000 to 170,000 miles, with many between 70,000 and 110,000 miles.

    Recall 07V226000

    What to check: Ask whether the fuel pressure sensor has been replaced and whether the car's VIN was included in recall 07V226000. On a test drive, watch for a flickering check engine light, hesitation, or a stumble when lifting off the throttle.

    2 excerpts from owner complaints in NHTSA records

    “The engine light came on in my 2004 Volvo s60r. The car would loose acceleration and also stalled. Volvo said it was the fuel pressure sensor and that it had been recalled by Volvo- recall # 07v226000. But the VIN # of my car was not included in the recall. It was the same part that was recalled on other 2004 s60s. Why not on the r as well?”

    NHTSA complaint #10376516, filed 2011-01, 75,000 miles

    “While driving 70 MPH, car lost acceleration and stalled without warning. If I would have been rear ended going at this speed I could have lost my life. Check engine light came on and all codes are associated with the 181 recall. Called Volvo and Volvo stated that this VIN number was not part of the recall yet I am experiencing the same exact problem and have the same exact engine codes when running a diagnostics test associated with this recall.”

    NHTSA complaint #10520078, filed 2013-06, 103,000 miles
  2. Engine

    Loss of power with check engine light / throttle body

    Mentioned in 8 of 60 sampled complaints

    Complaints describe the car losing power at road speed, sometimes showing a reduced-performance message, with the check engine light on or blinking. Shops named a range of findings across these reports, including a cracked intercooler hose, a failed electronic throttle body, throttle body cleaning, and engine wiring harness work, and in some cases the symptom returned after each repair. Some owners say the dealer could not duplicate the problem. Mostly reported between about 60,000 and 130,000 miles.

    What to check: Ask for service records showing whether the throttle body, intercooler hoses, or engine wiring have been worked on. During a test drive, accelerate onto a highway and watch for a hesitation or a check engine light.

    2 excerpts from owner complaints in NHTSA records

    “At any given time the vehicle stalls. I loose all power and have to restart the car. I've taken the car to the dealer they don't give me an answer. Finally they gave me a list of items that say may be the problem, but are not sure it's the problem.”

    NHTSA complaint #10430398, filed 2011-10, 99,000 miles

    “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. …”

    NHTSA complaint #11042866, filed 2017-11, 90,112 miles
  3. Electrical system

    Instrument panel and electrical faults

    • 9 complaints (5%)
    • median 95,100 mi at 8.3 yrs old (9 state mileage, few)
    • 1 mention a crash, fire or injury
    • filed 2008–2021

    Owners report the instrument panel going dark or stopping, taking the speedometer, odometer, and fuel gauge with it, and some describe multiple electrical functions dropping out together such as power locks, windows, and steering wheel controls. A few report the ignition key refusing to turn, requiring a tow and an ignition lock replacement. Reported from about 60,000 miles upward, with several cases past 100,000 miles.

    2 related service bulletins

    What to check: With the engine running, confirm every gauge and warning light works and that all windows, locks, and the key turn freely. Ask whether the battery and charging system have been tested recently.

    2 excerpts from owner complaints in NHTSA records

    “I have a 2004 Volvo S60 with 57,700 miles. All work on the vehicle has been done by Volvo. Recently, when the AC is on, the fan speed has stopped responding to adjustments. Nothing happens when I try to adjust the speed and then, on its own, the speed will change a few minutes later. When I turn the car off, the fan continues to run for at least five minutes. I'm afraid that one day it won't turn off and will drain the battery. …”

    NHTSA complaint #10232678, filed 2008-06, 57,780 miles

    “2004 Volvo S60 ignition key failure: key refused to turn car will not start. Car will not go in to neutral. Car must be abandoned occupants must seek transportation. First occurrence april 17th 2008. Second occurrence july 5th. 2010. Car towed to dealer and ignition lock replaced both times. Total cost $1662.48.”

    NHTSA complaint #10343456, filed 2010-07, 148,000 miles
  4. Fuel system

    Stalls and no-start traced to the fuel pump

    • 8 complaints (4%)
    • median 76,550 mi at 7.6 yrs old (8 state mileage, few)
    • filed 2007–2015

    Owners describe the car failing to start after turning the key, or stalling while driving and then not restarting until later. In several cases an independent mechanic diagnosed a failed fuel pump, and owners note their vehicle was not covered by the fuel pump recall for certain hot-weather states. Some had the pump replaced; others report no repair. Appears at higher mileage, mostly above 85,000 miles and often past 150,000 miles.

    Recall 09V483000

    What to check: Ask if the fuel pump has been replaced and check whether the car was registered in one of the states covered by recall 09V483000. Listen for a weak or absent priming hum when the key is turned on.

    2 excerpts from owner complaints in NHTSA records

    “March 2014: I was travelling on a divided highway at 55 MPH and the car stalled. Mechanic stated it was the fuel pump. Mar 2015 : this same event occurred again.”

    NHTSA complaint #10703247, filed 2015-04, 181,150 miles

    “The contact owns a 2004 Volvo S60. The contact stated that when turning the key into the ignition switch, the vehicle failed to start. The vehicle was towed to an independent mechanic who diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The vehicle was not included in NHTSA campaign number: 09v483000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 170,000.”

    NHTSA complaint #10778030, filed 2015-09, 170,000 miles
  5. Seats

    Driver seat heater scorching the seat

    Mentioned in 4 of 60 sampled complaints

    Two owners describe smoke coming from the driver's seat with the seat heater on, leaving a burn hole in the leather; one says the dealer removed the seat heater fuse and told them it was not covered. Other seat complaints concern the power seat moving to a stored position when the door is opened, which the dealer described as normal operation. Reported from very low mileage up to roughly 107,000 miles.

    What to check: Turn on the driver's seat heater briefly and check the seat cushion for burn marks, a melted spot, or a pulled fuse. Ask whether the heater has been repaired or disconnected.

    2 excerpts from owner complaints in NHTSA records

    “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.”

    NHTSA complaint #11400135, filed 2021-03, 165,000 miles

    “Driver's seat on 2004 Volvo s60r unexpectedly moves after unlocking car and opening the driver's door. Volvo says system is working as designed. They say that the seat must be moved to the desired position with the ignition turned on. If it is moved with the ignition off, it will return to the last position it was moved to with the ignition turned on every time the car is unlocked. There is almost a foot difference in height between my wife and me. …”

    NHTSA complaint #10079189, filed 2004-07, 12 miles

Buying note. These cars are old enough that service history matters more than mileage: ask specifically about the fuel pressure sensor and recall coverage, fuel pump replacement, and any throttle body or wiring work. A pre-purchase inspection by a shop familiar with Volvos, plus a check of open recalls by VIN, is worthwhile.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.

NHTSA recorded 198 consumer complaints for the 2004 Volvo S60. 172 of the complaints include a mileage, and 22% of those were filed for vehicles with under 50,000 miles; the median is 79,122 miles. Of all complaints, 12 involved a crash, 12 a fire, 8 an injury, according to the filers. NHTSA lists 5 recall campaigns and 174 technical service bulletins for this model year.

Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Also reported: Tires (9), Exterior lighting (7), Equipment (4), Body and structure (4), Suspension (3), Latches, locks and linkages (2), Seat belts (2), Visibility (wipers, defrost, mirrors) (2), Electronic stability control (1), Other or unknown (1).

Example complaints

Engine cooling: “I drive a Volvo s60r and when I am accelerating I notice that I have a very large lack of power going from 3000 to 3500 RPM's, there is almost no increase in power. I have brought up the issue with a Volvo dealer and they informed me that there was a recall for this, but my car for some reason did not get the recall. He said it is the same issue but there was nothing he can do about it.”

NHTSA complaint #10380825, filed 2011-02, 70,000 miles

Fuel system: “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.”

NHTSA complaint #10262478, filed 2009-03, 45,000 miles

Engine: “Approximate a month later after I brought 2004 Volvo S60 at dec 2011, when I was driving in freeway to post office, what a sudden, the engine stalled without warning, I press the accelerate pedal, but it was not response, but the car still hv a little momentum, then it turn it to the corner and the car was stopped. I turn off the key and restart the car again, it worked.after a year, the problem come back again and the frequency become more, up til dec, 2012, 3 more times same problem incurred. It was scary.”

NHTSA complaint #10487931, filed 2012-12, 78,500 miles

Electrical system: “Volvo s60r seat issue. Turned seat heater on, felt very warm sensation on my left hip/leg after a few minutes. Turned seat heater off and got out of car to check what was happening. Seat heater burned through the leather and also my jeans. Is there a recall/fix? Seems extremely dangerous.”

NHTSA complaint #10376515, filed 2011-01, 79,000 miles

Mileage when problems were reported

22% of the 172 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 53,000 and 107,000 miles.

6%0–102%10–2513%25–5023%50–7522%75–10024%100–15010%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (172 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 79,122 miles.

Complaints by year filed

Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.

’04’07’1032’13’16’20’24
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Crash test ratings

NHTSA's 5-Star Safety Ratings for the 2004 Volvo S60. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.

VersionOverallFrontalSideSide poleRollover
S60 · sedan not rated4 / 4——5 · 9.3% risk

Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.

Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.

Fuel economy and running cost

EPA ratings for each 2004 Volvo S60 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
S60 AWD2.5L 5-cyl5-speed automatic182520$4,100
S60 FWD2.3L 5-cyl5-speed manual182521$3,900
S60 FWD2.3L 5-cyl5-speed automatic182621$3,900
S60 FWD2.4L 5-cyl5-speed automatic192822$3,750
S60 FWD2.4L 5-cyl5-speed manual192722$3,750
S60 FWD2.5L 5-cyl5-speed automatic192722$3,750
S60 R AWD2.5L 5-cyl6-speed manual162319$4,350
S60 R AWD2.5L 5-cyl5-speed automatic162319$4,350

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

Recall details for the 2004 Volvo S60 → · Check a VIN at nhtsa.gov/recalls

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 174 on record; the latest 10 are shown.

See all 174 bulletins →

Other model years of the Volvo S60

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
20242213,0004530—Too new
20221542,0004530—Rising
20218—3527—Not enough data
20201211,7506527—Not enough data
20192515,3005—2857 · TypicalStable
20171742,4276529—Stable
20162733,000452929 · FewerFalling
20155947,535252941 · TypicalRising
20142531,000352420 · FewerStable
20138753,000452467 · MoreFalling
201212178,500852394 · MoreFalling
2011513,1506—21—Not enough data
20097106,7503—22—Not enough data
20081051,5002—22—Not enough data
20072156,9182—22—Falling
20063146,5623—22Not compared (before 2008)Rising
20054455,5003—22Not compared (before 2008)Falling
200419879,1225—22Not compared (before 2008)Falling
200312079,6956—21Not compared (before 2008)Falling
200218689,1268—21Not compared (before 2008)Falling
200122380,5008—21Not compared (before 2008)Falling

All Volvo S60 model years · Best and worst years by complaints

Frequently asked questions

What are the most common problems with the 2004 Volvo S60?

Owners of the 2004 Volvo S60 most often describe the engine cutting out while driving, frequently traced by shops to a fuel pressure sensor, and many say the dealer told them their VIN was not included in the related fuel pressure recall. The issues reported most often: Engine stalls or loses power while driving (fuel pressure; Loss of power with check engine light / throttle body; Instrument panel and electrical faults.

How many NHTSA complaints does the 2004 Volvo S60 have?

NHTSA recorded 198 consumer complaints for the 2004 Volvo S60 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Volvo S60 is reported most often?

Engine cooling is named most often, in 63 complaints (32% of the total), followed by fuel system with 55.

Has the 2004 Volvo S60 been recalled?

NHTSA lists 5 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Volvo S60 get?

The EPA rates the 2004 Volvo S60 (S60 FWD, 2.4L 5-cyl) at 22 mpg combined, 19 city and 28 highway, with an estimated annual fuel cost of $3,750 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 Volvo S60 reported?

Among the 172 complaints that include a mileage, the median is 79,122 miles and the middle half falls between 53,000 and 107,000 miles; 22% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.