CarBrief

Owners have filed 198 complaints with NHTSA for this car[1]. The engine group is named most often[2].

198owner complaints[1]
5recalls[3]
19–22MPG combined (EPA)[4]

Most reported problems

Here are the complaint groups owners name most often, biggest first. - Engine. 85 complaints[2]. Owners describe the car stalling or shutting off while driving, sometimes in traffic or at highway speed. Some also describe losing power steering or braking help during a stall, and dealers struggling to find a cause. - Fuel System, Gasoline. 30 complaints[5]. In the stories we read, owners describe the car dying on the highway, fuel smells and leaking fuel pumps. Some say the car kept hesitating after a pump repair. - Electrical System. 21 complaints[6]. Owners describe bulbs that keep burning out, a climate fan that acts on its own, ignition key trouble and a turn signal that works only part of the time. - Fuel/Propulsion System. 18 complaints[7]. Owners describe stalls tied to fuel injectors, fuel pressure sensors and fuel pumps, plus a check engine light and lost power. - Power Train. 12 complaints[8]. Owners filed these reports early in the car's life. - Seats. 12 complaints[9]. Owners describe seat heaters getting too hot, and fires are reported in this group[9]. - Speed Control. 11 complaints[10]. Crashes are reported in this group[10]. - Tires. 9 complaints[11]. Owners filed these reports at fairly low mileage.

Recalls

Newest first. Each recall covers only certain vehicles, so not every 2004 S60 is necessarily included.

Fuel economy

EPA ratings depend on the engine and drive. Annual fuel cost uses EPA's current fuel price assumptions, not prices when the car was new.

Version City / highway / combined MPG Annual fuel cost
S60 AWD, 2.5L 5-cyl turbo, Automatic 5-spd, Premium, 4-Wheel or All-Wheel Drive[17] 18 / 25 / 20 $4,100
S60 FWD, 2.3L 5-cyl turbo, Manual 5-spd, Premium, Front-Wheel Drive[18] 18 / 25 / 21 $3,900
S60 FWD, 2.3L 5-cyl turbo, Automatic (S5), Premium, Front-Wheel Drive[19] 18 / 26 / 21 $3,900
S60 FWD, 2.4L 5-cyl, Automatic 5-spd, Premium, Front-Wheel Drive[4] 19 / 28 / 22 $3,750
S60 FWD, 2.4L 5-cyl, Manual 5-spd, Premium, Front-Wheel Drive[20] 19 / 27 / 22 $3,750
S60 FWD, 2.5L 5-cyl turbo, Automatic 5-spd, Premium, Front-Wheel Drive[21] 19 / 27 / 22 $3,750
S60 R AWD, 2.5L 5-cyl turbo, Manual 6-spd, Premium, 4-Wheel or All-Wheel Drive[22] 16 / 23 / 19 $4,350
S60 R AWD, 2.5L 5-cyl turbo, Automatic (S5), Premium, 4-Wheel or All-Wheel Drive[23] 16 / 23 / 19 $4,350

Safety ratings

Version Overall Frontal Side Rollover Rollover risk
4 DR None[24] n/a n/a n/a 5 9.3%

Engine and size

These are Canadian-market specifications from Transport Canada, so US models can differ slightly.

Version Length Width Height Wheelbase Curb weight
S60 4DR SEDAN 2.4/ 2.4T/ T5[25] 181 in 71 in 56 in 107 in 3,175 lb
S60 4DR SEDAN AWD[26] 181 in 71 in 56 in 107 in 3,311 lb
S60R 4DR SEDAN AWD[27] 182 in 71 in 56 in 107 in 3,609 lb

How 2004 compares with other years

2001: 223 complaints, 8 recalls20012002: 186 complaints, 8 recalls2003: 120 complaints, 6 recalls20032004: 198 complaints, 5 recalls19820042005: 44 complaints, 3 recalls20052006: 31 complaints, 3 recalls2007: 21 complaints, 2 recalls20072008: 10 complaints, 2 recalls2009: 7 complaints, 3 recalls20092011: 5 complaints, 6 recalls2012: 121 complaints, 8 recalls20122013: 87 complaints, 4 recalls2014: 25 complaints, 3 recalls20142015: 59 complaints, 2 recalls2016: 28 complaints, 4 recalls20162017: 18 complaints, 6 recalls2018: 4 complaints, 1 recalls20182019: 25 complaints, 5 recalls2020: 12 complaints, 6 recalls20202021: 8 complaints, 3 recalls2022: 15 complaints, 4 recalls20222023: 3 complaints, 7 recalls2024: 22 complaints, 4 recalls2024
Owner complaints filed with NHTSA for each S60 model year. The 2004 is highlighted[3].
Show the numbers
Model yearComplaintsRecalls
20012238
20021868
20031206
20041985
2005443
2006313
2007212
2008102
200973
201156
20121218
2013874
2014253
2015592
2016284
2017186
201841
2019255
2020126
202183
2022154
202337
2024224

NHTSA's counts for the S60 show 198 complaints and 5 recalls for 2004[3]. Among the 24 model years listed, 22 have fewer complaints than 2004 and 1 have more[3]. The fewest complaints are for 2025 (0) and the most are for 2001 (223)[3]. These counts are not adjusted for sales, so treat them as a rough guide. The chart above shows every year.

Should you buy a used 2004 S60?

The complaint record for this sedan centers on engines that stall and on fuel system trouble[2][5]. Electrical gripes come next[6]. These are unverified owner reports to NHTSA, and they are not adjusted for how many cars were sold[1]. Recalls also exist for this year, so check the Recalls section on this page[3]. If you are shopping for one, look closely at how the engine runs and ask for fuel system service records.

Frequently asked questions

What are the most common problems with the 2004 Volvo S60?
Owners name the engine group most often, followed by the gasoline fuel system and the electrical system[2][5][6].
Does the 2004 Volvo S60 have recalls?
Yes, recalls exist for this year[3]. See the Recalls section on this page for the list.
How many complaints has the 2004 Volvo S60 had?
NHTSA has 198 owner complaints on file[1].
What is the gas mileage of the 2004 Volvo S60?
See the fuel economy section on this page. It is generated from EPA data.
Is the 2004 Volvo S60 reliable?
Stalling and fuel system reports stand out in the owner complaints[2][5]. Check the safety and by-year sections on this page too.

Keep exploring

Other model years of the Volvo S60

Compare all model years of the Volvo S60

Other Volvo models from 2004

All Volvo models

Similar cars from 2004: compact cars

All compact cars we cover

Facts and sources

  1. NHTSA has 198 owner complaints on file for the 2004 Volvo S60 (12 mention a crash, 12 a fire, 8 injuries, 0 deaths reported). NHTSA vehicle records
  2. 85 complaints name the engine component group (3 crashes, 1 fires, 1 injuries, median mileage at failure 81,025). NHTSA vehicle records
  3. Owner complaints and recalls for every Volvo S60 model year (chart above). NHTSA recall database
  4. EPA rating for S60 FWD, 2.4L 5-cyl, Automatic 5-spd, Premium, Front-Wheel Drive: 19 city / 28 highway / 22 combined MPG; EPA estimated annual fuel cost $3,750. EPA / DOE fueleconomy.gov
  5. 30 complaints name the fuel system, gasoline component group (1 crashes, 0 fires, 1 injuries, median mileage at failure 77,000). NHTSA vehicle records
  6. 21 complaints name the electrical system component group (0 crashes, 4 fires, 0 injuries, median mileage at failure 101,165). NHTSA vehicle records
  7. 18 complaints name the fuel/propulsion system component group (0 crashes, 0 fires, 0 injuries, median mileage at failure 121,500). NHTSA vehicle records
  8. 12 complaints name the power train component group (1 crashes, 0 fires, 1 injuries, median mileage at failure 30,000). NHTSA vehicle records
  9. 12 complaints name the seats component group (0 crashes, 9 fires, 1 injuries, median mileage at failure 107,000). NHTSA vehicle records
  10. 11 complaints name the speed control component group (3 crashes, 0 fires, 0 injuries, median mileage at failure 92,058). NHTSA vehicle records
  11. 9 complaints name the tires component group (0 crashes, 0 fires, 0 injuries, median mileage at failure 27,250). NHTSA vehicle records
  12. Recall 21V766, filed September 30, 2021: Air Bags › Frontal › Driver Side › Inflator Module. NHTSA recall database
  13. Recall 10V566, filed November 8, 2010: Equipment › Electrical › Navigational System(Global Positioning System). NHTSA recall database
  14. Recall 09V483, filed December 18, 2009: Fuel System, Gasoline › Delivery › Fuel Pump. NHTSA recall database
  15. Recall 07V226, filed June 5, 2007: Engine And Engine Cooling. NHTSA recall database
  16. Recall 04V029, filed January 16, 2004: Steering › Linkages. NHTSA recall database
  17. EPA rating for S60 AWD, 2.5L 5-cyl turbo, Automatic 5-spd, Premium, 4-Wheel or All-Wheel Drive: 18 city / 25 highway / 20 combined MPG; EPA estimated annual fuel cost $4,100. EPA / DOE fueleconomy.gov
  18. EPA rating for S60 FWD, 2.3L 5-cyl turbo, Manual 5-spd, Premium, Front-Wheel Drive: 18 city / 25 highway / 21 combined MPG; EPA estimated annual fuel cost $3,900. EPA / DOE fueleconomy.gov
  19. EPA rating for S60 FWD, 2.3L 5-cyl turbo, Automatic (S5), Premium, Front-Wheel Drive: 18 city / 26 highway / 21 combined MPG; EPA estimated annual fuel cost $3,900. EPA / DOE fueleconomy.gov
  20. EPA rating for S60 FWD, 2.4L 5-cyl, Manual 5-spd, Premium, Front-Wheel Drive: 19 city / 27 highway / 22 combined MPG; EPA estimated annual fuel cost $3,750. EPA / DOE fueleconomy.gov
  21. EPA rating for S60 FWD, 2.5L 5-cyl turbo, Automatic 5-spd, Premium, Front-Wheel Drive: 19 city / 27 highway / 22 combined MPG; EPA estimated annual fuel cost $3,750. EPA / DOE fueleconomy.gov
  22. EPA rating for S60 R AWD, 2.5L 5-cyl turbo, Manual 6-spd, Premium, 4-Wheel or All-Wheel Drive: 16 city / 23 highway / 19 combined MPG; EPA estimated annual fuel cost $4,350. EPA / DOE fueleconomy.gov
  23. EPA rating for S60 R AWD, 2.5L 5-cyl turbo, Automatic (S5), Premium, 4-Wheel or All-Wheel Drive: 16 city / 23 highway / 19 combined MPG; EPA estimated annual fuel cost $4,350. EPA / DOE fueleconomy.gov
  24. NHTSA 5-Star Safety Ratings, 4 DR None: rollover 5 stars; rollover risk 9.3%. NHTSA vehicle records
  25. Transport Canada specifications via NHTSA vPIC, S60 4DR SEDAN 2.4/ 2.4T/ T5: length 181 in, width 71 in, height 56 in, wheelbase 107 in, curb weight 3,175 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
  26. Transport Canada specifications via NHTSA vPIC, S60 4DR SEDAN AWD: length 181 in, width 71 in, height 56 in, wheelbase 107 in, curb weight 3,311 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
  27. Transport Canada specifications via NHTSA vPIC, S60R 4DR SEDAN AWD: length 182 in, width 71 in, height 56 in, wheelbase 107 in, curb weight 3,609 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov

Complaints submitted to NHTSA by owners; unverified reports, one complaint can name several components. Complaint counts are not normalized by sales; compare years of the same model, not different models. EPA annual fuel cost uses EPA's current fuel price assumptions, not the price when the car was new. Horsepower is the rating listed for EPA test vehicles. Dimensions are Canadian-market specifications and can differ slightly from US models.