2004 Volvo S60: Recalls, Problems & MPG
Here are the deets on the 2004 Volvo S60: 5 recalls, 198 owner complaints and up to 22 mpg combined.
Recalls
5 vehicle recalls from the manufacturer, plus 1 equipment/tire recall that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Steering Vehicle recall #04V029000 · 2004 · 29,986 vehicles
What's wrong: 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.
Why it matters: This driving condition could eventually lead to separation between the front control arm and the spindle, which could result in a crash.
The fix: 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.
Engine & cooling Vehicle recall #07V226000 · 2007 · 32,189 vehicles
What's wrong: 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…
Why it matters: 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.
The fix: Dealers will replace the fuel pressure sensor free of charge. The recall began on June 29, 2007.
Fuel system Vehicle recall #09V483000 · 2009 · 158,733 vehicles
What's wrong: 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.
Why it matters: 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.
The fix: 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.
Equipment Vehicle recall #10V566000 · 2010 · 416 vehicles
What's wrong:
Why it matters: An overheated battery could lead to a fire.
The fix: 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…
Airbags Vehicle recall #21V766000 · 2021 · 259,383 vehicles
What's wrong: 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.
Why it matters: An inflator explosion May result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
The fix: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021.
1 aftermarket equipment / tire recall replacement parts sold to fit this car, not the car itself
Brakes (hydraulic) Equipment recall #07E023000 · 2007 · 13,128 vehicles
What's wrong: Certain cardone master cylinders with part numbers 10-2925, 10-2987, 10-2987mza, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, and 11-3156, and with date codes lower than dca7078 sold as replacement equipment for use on the vehicles listed above. The seal on master cylinder can fail and leak brake fluid.
Why it matters: Loss of brake fluid can result in poor braking performance, possibly resulting in a vehicle crash.
The fix: Cardone will notify owners and offer to repurchase any defective master cylinders. The recall began during April 2007. Owners can contact cardone at 1-800-777-4780.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 12 mention a fire, 8 injuries and 0 deaths were reported.
What owners describe
- Engine & cooling (63): the most common themes are stalls / loses power (45), warning light on (28).
- Fuel system (30): the most common themes are stalls / loses power (19), warning light on (11).
- Engine (22): the most common themes are stalls / loses power (15), warning light on (11).
- Electrical (21): the most common themes are door / lock issues (9), warning light on (9), electrical failure (6).
The 2004 Volvo S60 has 198 owner complaints, ranking #2 of 25 S60 model years for complaints (3.9× the average S60 year). Complaints peaked in 2010 (32 filed that year). The typical problem showed up when the car was about 6 years old, at a median of 79,122 miles. Neighboring years: 2003 (120 complaints, 6 recalls), 2005 (44 complaints, 3 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 2.4 L 5-cyl | Automatic 5-spd | Front-Wheel Drive | 19 | 28 | 22 | Premium |
| 2.4 L 5-cyl | Manual 5-spd | Front-Wheel Drive | 19 | 27 | 22 | Premium |
| 2.5 L 5-cyl turbo | Automatic 5-spd | Front-Wheel Drive | 19 | 27 | 22 | Premium |
| 2.3 L 5-cyl turbo | Manual 5-spd | Front-Wheel Drive | 18 | 25 | 21 | Premium |
| 2.3 L 5-cyl turbo | Automatic (S5) | Front-Wheel Drive | 18 | 26 | 21 | Premium |
| 2.5 L 5-cyl turbo | Automatic 5-spd | 4-Wheel or All-Wheel Drive | 18 | 25 | 20 | Premium |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 2004 Volvo S60.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
From $19.99/mo · $39.99/yrOEM procedures, specs and recall/TSB info, the same source many shops use.
From $19.99/mo · $59.99/yrStep-by-step photos written from a real teardown. Great for first-timers.
Books ~$30–$40 · AllAccess $34.99/moHeads up: we may earn a commission if you buy through these links, at no extra cost to you. Prices checked 2026-10 and can change. We never host or link to pirated manuals. Disclosure
FAQ
Does the 2004 Volvo S60 have any recalls?
Yes. NHTSA lists 5 vehicle recalls for the 2004 Volvo S60, plus 1 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 2004 Volvo S60 problems?
Owners have filed 198 complaints with NHTSA. The most-reported areas are engine & cooling (63), fuel system (30), engine (22).
What gas mileage does the 2004 Volvo S60 get?
EPA ratings run up to 22 mpg combined (2.4 L, Automatic 5-spd), across 6 engine and transmission combos.
Where can I get a 2004 Volvo S60 repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.