Problems owners report
Complaints filed with NHTSA about the 2004 Volvo S60, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling63
- Fuel system, gasoline30
- Engine22
- Electrical system21
- Fuel/propulsion system18
- Power train12
- Seats12
- Vehicle speed control11
- Steering9
- Air bags9
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 8 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 13 2004 S60 vehicles were involved in crashes on US public roads in which someone died; 9 people died inside them, and 2 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Volvo S60 failed the safety check 2.99% of the time — 36% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 141,226 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Engines
The most common engines in 2004 Volvo S60 cars on Dutch roads are the 2.4 petrol (103 kW, 138 hp), 2.0 petrol (132 kW, 177 hp) and 2.4 petrol (125 kW, 168 hp), out of 6 versions with at least 20 cars.
| Engine | Power | Cars |
|---|---|---|
| 2.4 petrol | 103 kW 138 hp | 374 |
| 2.0 petrol | 132 kW 177 hp | 136 |
| 2.4 petrol | 125 kW 168 hp | 116 |
| 2.5 petrol | 154 kW 207 hp | 65 |
| 2.4 diesel | 120 kW 161 hp | 26 |
| 2.5 petrol | 220 kW 295 hp | 20 |
RDW Open Data (CC0): registered passenger cars and their fuel data · engine size rounded to 0.1 litre, net maximum power · versions with at least 20 cars
In the Netherlands
784 first registered in 2004 are on Dutch roads; 10% arrived later as imports. Median list price when new: €48,565.
Most common APK defects
- Bandenspanning niet op juiste waarde386
- Band onvoldoende profiel313
- Kentekenplaatverlichting werkt niet (goed) / ontbreekt312
- Stadslicht werkt niet (goed)232
- Stofhoes aandrijfas beschadigd en dicht niet af228
- Band(en) aanwezig met een profieldiepte van 1,6 t/m 2,5 mm190
- Dimlicht onjuist afgesteld190
- Overmatige vloeistoflekkage overige vloeistoffen184
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In the United Kingdom
768 cars built in 2004 were licensed for the road at the end of 2025, and 614 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
MOT test results in Great Britain
In 2023, 1,334 of these cars first registered in 2004 took their annual MOT test. 58% passed first time; among all cars first registered in 2004 the figure was 56%.
| Failed on | These cars | All cars from 2004 |
|---|---|---|
| Lamps, reflectors and electrical equipment | 25.6% | 21.8% |
| Brakes | 15.6% | 13.8% |
| Suspension | 9.7% | 17.2% |
| Tyres | 8.1% | 6.7% |
| Body, chassis, structure | 6.4% | 9.1% |
| Steering | 5.1% | 4.5% |
DVSA anonymised MOT tests and results, 2023 (Department for Transport) · Open Government Licence v3.0 · first tests only; a fix made at the test station within the hour still counts as a fail
In Finland
1,028 of these cars first registered in 2004 were in use in Finland on 30 Jun 2026, with an average of 312,000 km on the odometer at their last inspection.
Traficom (Finnish Transport and Communications Agency), open data on vehicles in use · CC BY 4.0
In New Zealand
28 2004 cars are on the New Zealand register; 50% arrived as used imports, 50% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 8 variants: combined 10.4–12.7 L/100 km (about 19–23 mpg US), CO₂ 239–292 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| S60 · Compact · Premium gasoline | 12.1 | 8.3 | 10.4 |
| S60 · Compact · Premium gasoline | 12.2 | 8.7 | 10.6 |
| S60 2.5T Turbo · Compact · Premium gasoline | 12.3 | 8.6 | 10.6 |
| S60 T5 Turbo · Compact · Premium gasoline | 13.1 | 9.3 | 11.4 |
| S60 T5 Turbo · Compact · Premium gasoline | 13.0 | 9.5 | 11.4 |
| S60 2.5T AWD Turbo · Compact · Premium gasoline | 13.2 | 9.4 | 11.5 |
| S60 R AWD Turbo · Compact · Premium gasoline | 14.8 | 10.2 | 12.7 |
| S60 R AWD Turbo · Compact · Premium gasoline | 14.7 | 10.2 | 12.7 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
4 Transport Canada recalls for the 2004 Volvo S60.
| 2010396 8 Nov 2010 | Accessories On certain vehicles, there is a possibility of overheating issues of batteries in the Garmin nüvi® 760 when certain batteries manufactured within a limited date… |
| 2007167 24 May 2007 | Fuel System On certain vehicles, the fuel pressure sensor may at times transmit an incorrect signal to the Engine Control Module (ECM). If the signal is outside of the pre… |
| 2004017 19 Jan 2004 | Suspension On certain vehicles, the front lower control arms may not have been manufactured within the agreed specifications and as a result the stud and nut that secure t… |
| 2003226 12 Sept 2003 | Other Certain vehicles do not comply with CMVSS 210.2. The symbol indicating the presence of a lower universal anchorage system, and a reproduction of this symbol we… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
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.
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.
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Volvo told its dealers about the 2004 Volvo S60: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 11007925 | Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service |
| 10249191 | This is a Technical Journal: 12V Battery Testing Method |
| 10241661 | COMPLIMENTARY UPGRADE C00009 DESCRIPTION. |
| 10241651 | Rubber cushion |
| 10219421 | Engine Control Module (EMS) Software (MSW) Information August 2022; Improvement List (Change Log) - US21+OBD22 (13L VGT, TC) And US17+OBD22 (11L) Emissions |
| 10213885 | The Deutronic DBL-1200 is an advanced battery maintainer/charger with the flexibility to be updated as products and repair methods evolve. |
| 10213883 | ICUP/Google Built-In Diagnostic Operations |
| 10213882 | Battery Charger/maintainer requirement |
| 10212892 | Shipping and Handling of Volvo Lithium-ion 48V Mild Hybrid Battery to Global Battery Solutions (GBS) |
| 10212891 | VIDA QR Scanner Mobile App |
| 10202436 | New Software Products (SP) have been developed to convert a Care Key to a standard key. |
| 10188881 | Volvo?s Warranty Department tracks Retailer warranty spending by utilizing the Warranty Retailer Counseling Process (WRCP). The WRCP is used to gauge individual retailer performance on objective measures over time. By setting clear performance expectations and parameters and assisting retailers in focusing on individual processes and procedures, all retailers are provided with adequate tools to help achieve the ultimate goal of qualifying for self-authorization status. |
| 10181041 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
| 10179681 | This is a Service Manager Bulletin: Service 2.0 Software & Total Upgrade Reminder |
| 10177386 | Service Manager Bulletin: Vehicle Type and Platform Information |
| 10173760 | This is a Service Manager Bulletin: Service 2.0 Software & Total Upgrade Reminder |
| 10171676 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
| 10170147 | Service Manager Bulletin TITLE : Service Action Notification Re - Mails GROUP : NO : ISSUING DEPARTMENT : CAR MARKET : Product Safety & Compliance United States and Canada 00 325 REFERENCE BULLETINS : DATE : SMB00 - 323 and SMB00 - 323A YEAR MONTH DAY SERVICE SERVICE WARRANTY 2013 02 15 MANAGER WRITER ADMINISTRATOR Service Personnel : Read and initial Page 1 of 1 Volvo monitors completion rates for all service actions and will complete notification re - mails to vehicle owners when necessary . Listed below are the latest notification re - mails . Please refer to SMB 00 - 323 and SMB 00 - 323A |
| 10169394 | This is a Technical Journal: Swapping control modules from vehicle to vehicle for diagnostics should be avoided. Swapping control modules may result in consequential damage to the swapped control module and in certain cases several other control modules in the vehicle. Swapping the Driver Information Module (DIM) is strictly forbidden as the DIM it is the main carrier of the odometer function, and will, in case of swapping, result in manipulated odometer value. Service: Please do NOT swap any control modules from vehicle to vehicle for testing, unless instructed to do so in a Vehicle Report by |
| 10169393 | This is a Technical Journal: Swapping control modules from vehicle to vehicle for diagnostics should be avoided. Swapping control modules may result in consequential damage to the swapped control module and in certain cases several other control modules in the vehicle. Swapping the Driver Information Module (DIM) is strictly forbidden as the DIM it is the main carrier of the odometer function, and will, in case of swapping, result in manipulated odometer value. Service: Please do NOT swap any control modules from vehicle to vehicle for testing, unless instructed to do so in a Vehicle Report by |
| 10169391 | Software Installation Policy changes. |
| 10169390 | Effective immediately, all 12V batteries may be tested using the hand held battery tester 9513030 (BT3300). The VIDA test is still available but no longer required. For battery replacements under warranty, the code generated by the BT3300 must be manually copied into the repair order text. It must also be printed and attached to the hard copy of the repair order. |
| 10169389 | This is a Service Manager Bulletin: Technician Skillset Requirments |
| 10169388 | This is a Technical Journal: This Journal is a guide for performing Software Downloads. Service: *See guide updated Oct. 12, 2016 for relevant P5/SPA Software Download information: P5_SPA_SW_Guide.pdf See VIDA Software tab for all other vehicles.The attached checklists can be used for restoring customer settings, where applicable. |
| 10169036 | Mandatory Tool List bulletin: Volvo mandatory Special Tools are necessary for technicians to properly diagnose and repair Volvo cars. They are used in development of Volvo labor operations and repair methods, and promote safety and quality repairs in a timely manner. Tools are classified as mandatory because associated repairs and/or diagnostics cannot be completed properly without them. |
NHTSA manufacturer communications (public domain)