2004 Volvo S60 Volvo S60 2004

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2004 Volvo S60 repairs by problem area

Engine (27%)

Transmission and Drivetrain (10%)

Brakes and Traction Control (5%)

Suspension and Steering (29%)

Electrical and Air Conditioning (16%)

Paint, Rust, Leaks, Rattles, and Trim (6%)

Other (7%)

Chart based on 348 repairs.
See TSBs and recalls for the 2004 Volvo S60.

2004 Volvo S60 engine repair cost distribution

$2500+ (4%)

$1000 - $2499 (16%)

$500 - $999 (14%)

$100 - $499 (42%)

< $100 (24%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 79 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2004 Volvo S60

Engine not specified

32000 mi Car wouldn't start. 3rd time in 6 months its been towed to the shop because of computer problems, supposedly fixed this time. 

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2004 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed manual AWD

70000 mi

US $435
Fuel pressure rail sensor went bad causing check engine light and slight stumbling... 
71000 mi

US $153
CEL came on. Had to reflash OBD system to latest version. Claimed intermittent fault in cooling system that will be fixed when component finally fails... 
76000 mi

US $653
Top engine/motor/transmission mount was replaced due to wear. It allowed the engine to move with regard to the transmission so there was a clunk noise when shifting 1-2. 
69500 mi

US $500
Engine stumbled in 5&6 gear at 10-12 lbs boost. Thought was fuel delivery problem but no engine light and over a week of diagnostics revealed nothing. Minor tune-up items installed w/out affect. Suggested dealer for repair, trip 2. Unresolved prob.1. Dlr usd more sophist diagnostic eqpmnt to ID problem as cracked coils 3of5) and replaced thm. Car now runs as new. 
128000 mi

US $300
Fuel pump sealing ring cracked. Fuel pump replaced. 
52080 mi Faulty fuel pressure sensor - covered under a recall notice.| 
37000 mi Noted small piece of plastic broke off Fuel Cover. It is slightly loose now but still works. Did not repair. 
70000 mi

US $600
Replaced 3 faulty ignition coils 
66000 mi

US $150
Replaced two ignition coils and all spark plugs due to misfire. 
84000 mi

US $1900
Replace leaking coolant overflow reservoir. 
112000 mi

US $600
Timing belt, idlers, water pump, serpentine belt, spark plugs, upper engine mount 
143000 mi

US $350
Replaced crank case vent system including hoses and plastic tank located under intake manifold. Replaced hoses for the fuel evaporation system on the engine which were in poor shape. Replaced thermostat since I had to remove for other work. 
156000 mi

US $140
Car was stumbling and would only go about 15MPH because throttle position sensor was bad. Since it was built into the throttle body (non-repairable) had to replace entire unit for cost $140 used. New was over $600 just for parts. Common problem for high mileage Volvo cars. 
159000 mi

US $400
Replaced front pipe and converter. Installed replacement flange on rear pipe which bolts to the back of the converter. Purchased new Walker pipe/converter, quality was poor requiring filing and grinding to remove excessive weld splatter which cause problems installing the O2 sensor and sealing the flange to the turbo. Resulted in about 3 hours extra work. Front flex pipe failed on OEM system. 
99000 mi

US $2600
Replaced timing belt, tensioner and water pump. Also replaced accessory drive belt and tensioner--latter had started to fail. 

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2004 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 5-speed shiftable automatic AWD

128680 mi

C $91
replaced coil pack #1....this is the 3rd pack for this cylinder, other coil packs are fine. 
185480 mi

C $1500
recurring misfire on cylinder #1...thought to be coil pack. Replaced CP twice but po301 recurred. Some CP's had cracked boots, replaced all CP's. Did not cure misfire..,found out I ahd a bad injector in cyl #1...replaced all CPs and injectrs 
207700 mi

C $1200
new timing belt and water pump 
223200 mi

C $450
replaced serpentine belt idler pulley 
95000 mi Engine will start then stall and then no longer start. More warning lights to list than character will allow me to enter. On going problem with no resolution yet. Still at dealer 
134000 mi Turbo intercooler hose crack and letting in air reducing performance and leading to hard starting Code 0073 and ABS warning. Car will turn over but won't catch after heavy city driving. After 30 min. car runs but keeps showing code. 
90000 mi

US $80
Ignition coil. 
70000 mi

US $225
Fuel rail pressure sensor 1 went bad car wouldn't start in heated garage over winter it was pushed outside and started right up odd deal fixed now though  
82000 mi

US $200
Fuel pressure sensor number one went out. Car wouldn't start in heated garage only in cold.  
56000 mi

US $300
Replace fuel pressure sensor 
69000 mi

US $650
Car suddenly began running rough. Went ASAP to repair shop; diagnostic said "misfire in #3 cylinder". Replaced all 5 ignition coils. Subsequent 2000 mile trip showed smooth running and slightly better fuel mileage. 

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2004 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed shiftable automatic FWD

133000 mi low coolant level sensor warning w/o car overheating. slow loss of coolant but shop was unable to find leak. 
137000 mi

US $300
Problem finally diagnosed as head gasket leak only active when engine is warm and coolant becomes pressurized due to heat. Car in shop for 20 days, other dry gasket or questionable seals found while engine was apart. Now being repaired. Picked up car after shop reported head gasket leak repaired. Driven for 3 days and coolant level falling again. Returned to shop. Diagnosed with cracked thermostat housing. Replaced. Coolant system now operating properly. 
141000 mi loose connection from previous repair caused minor leak in coolant system. repaired and now functioning properly. 
100000 mi

US $300
Ignition coils replaced 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD

168600 mi

US $6500
Replace Catalytic Converter 165000 mi service Replace Turbo return pipe seals 
197200 mi

US $2092
Engine oil leak near timing belt Replace lower engine mount 
109100 mi

US $1000
Replace radiator 
142000 mi

US $750
Crankshaft seal replaced.  Front engine mount replaced 
65000 mi

US $1600
RADIATOR AND REAR BRAKES 
109120 mi

C $450
MAF replaced, 2nd time within 18 months, intake manifold cleaned. 
72000 mi

US $35
oil filter cannister loosened after 1500 miles and gushed on the street. Replaced filter and cartridge and tightened with wrench instead of hand tighten. Had to use CarChip to shut off "Check Engine Light" 
92000 mi

US $750
broken exhaust bracket 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD

72000 mi Catastrophic failure of the engine due to sludge - secondary to poor maintenance by prior owner. 
49600 mi

C $200
Replace centre engine mount. 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic FWD

95000 mi

US $100
Engine mount bushings were worn out; new upper engine mounts (with new design) installed. Lower transmission mount bushing worn out. Mount replaced with new part of a new design. 
178300 mi

US $1200
Replace mass airflow sensor 
83000 mi

US $437
Leak Detection Pump replaced. 
31400 mi

US $200
Gear/turbo upshifting from 2nd to 3rd gear causing a lurch during driving. The throttle body was cleaned and software updated. Clean throttle body and update fuel delivery software due to lag when shifting between 1st and second gear. 
106600 mi

US $1300
Leaking oil from head gasket 
115000 mi

US $1133
Clogged crankcase breather system, cleaned out oil residue on engine block and oil pick-up tube/screen assembly which was clogged. Cleared camshaft solenoids and oil ports and replaced gaskets. 
136000 mi

US $139
Front engine mount broken 
71300 mi

$85
Cleaning of throttle body 
35340 mi Replace fuel pressure sensor (as per Volvo recall campaign # R181) due to faulty design. New fuel pressure sensor of modified design installed. 
57040 mi

C $139
Replaced upper radiator cooling hose. Replaced upper radiator cooling hose. 
73160 mi

C $1600
Check engine light. MAF worn out. Mass air flow sensor replaced. During same visit found that PCV system was plugged. Entire PCV system replaced with new one. Check engine light. MAF worn out. Mass air flow sensor replaced.rnrnDuring same visit found that PCV system was plugged. Entire PCV system replaced with new one.rn 
78120 mi

C $120
Replace worn bolt on transmission mount. Replace worn bolt on transmission mount. 
93620 mi

C $300
Replaced ignition lock cylinder. Original one was starting to stick when the key was turned. 
94240 mi

C $600
replacement of worn engine mount. replacement of failed power steering system valve, fluid reservoir, and hose. 
100440 mi

C $92
Replaced turbo control valve 
185800 mi

US $1024
New radiator New cam oil seal New engine mount - old one broke 
72000 mi

US $350
Replaced radiator. 
103000 mi Had a problem with an intermittent check engine light flagged as the MAP sensor (P2207). Dealer said to fix, but independent mechanic that the code was in error. 
112500 mi

US $400
Replaced all engine mounts, transmission mount, and subframe bushings as they were very badly worn out. 
130000 mi

US $150
Engine codes for the MAP sensor were returned once more. The shop ran some diagnostics and flashed the software, but car started exhibiting a new problem of occasional violent shaking. Shop said that this was an "old" problem, charged 150. 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic AWD

86800 mi ECU module defective. replaced with brand new. ECU module reprogrammed 

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2004 Volvo S60 4dr Sedan

turbocharged 177hp 2.0L I5 5-speed manual FWD

119040 mi

R 29537
Engine mount Radiator leaking, Brake pads 

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2004 Volvo S60 4dr Sedan

turbocharged 161hp 2.4L I5 Diesel 5-speed shiftable automatic FWD

94000 mi

£500
Centre box hanger failure, repair part available from Volvo fitted. 

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2004 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed automatic FWD

266000 mi

US $753
MAP sensor Ignition Lock Cylinder 
238700 mi

£400
Intercooler replaced 
256000 mi

£350
Camshaft gasket replaced 
79379 mi

US $329
CEL ECM130A, 250A, 350Z, replace MAF meter, fuel injection service, replace spark plugs, ECM & CEM software upgrade 
109000 mi

US $300
The car stalled 2 times while driving. It was first diagnosed as the battery issue. Driving a week later, it happened again and was diagnosed as fuel pressure sensor issue. 
71200 mi

US $800
Ignition switch failed 
72000 mi

US $80
muffler mounting brackets rusted through, replaced brackets. 
142000 mi

US $1180
Broken CEM (Central Electronic Module): Dashboard didn't start up, Gearbox used just couple of higher forward gears. CEM replaced, all problems fixed. 
155000 mi

US $1150
Check engine light came on, fuel pressure sensor replaced 
160000 mi

US $500
Engine mount broken 
167000 mi Massive oil leak from rms 
160800 mi

US $100
Coil pack replaced 
165000 mi

US $56
Coil pack went bad 
215000 mi

US $60
Failed ignition coil pack. 

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See TrueDelta's information for all Volvo models.

2004 Volvo S60 Engine Problems

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2004 Volvo S60 problems occur, check out our car reliability stats.