2004 Volvo S60

Introduction:

The 2004 Volvo S60 is a compact luxury sedan that offers a sporty and refined driving experience. It is available with a variety of engine and transmission options, including a 2.4-liter naturally aspirated inline-5 engine producing 170 horsepower and 170 lb-ft of torque, a 2.5-liter turbocharged inline-5 engine producing 218 horsepower and 236 lb-ft of torque, and a 2.5-liter turbocharged inline-5 engine producing 300 horsepower and 295 lb-ft of torque. Transmission options include a 5-speed manual, a 5-speed automatic, and a 6-speed automatic.

Owners of the Volvo S60 generally praise the vehicle’s performance, handling, and safety features. However, it has also been reported to have some common issues.

Engine

2.4-liter Naturally Aspirated Inline-5

• Intake Manifold Failure:
  • Description/Symptoms: Cracks in the intake manifold can lead to vacuum leaks, engine misfires, and reduced power.
  • Solution: Replacement of the intake manifold.
  • Estimated Cost to Fix: $500 - $1,000+
• Crankshaft Position Sensor Failure:
  • Description/Symptoms: A faulty crankshaft position sensor can cause the engine to stall or fail to start.
  • Solution: Replacement of the crankshaft position sensor.
  • Estimated Cost to Fix: $200 - $400

2.5-liter Turbocharged Inline-5 (218 HP)

• Turbocharger Failure:
  • Description/Symptoms: A failing turbocharger can cause loss of power, increased exhaust smoke, and whistling noises.
  • Solution: Replacement of the turbocharger.
  • Estimated Cost to Fix: $1,500 - $2,500+

2.5-liter Turbocharged Inline-5 (300 HP)

• No Issues Found

Transmission

5-Speed Manual

• No Issues Found

5-Speed Automatic

• Transmission Fluid Leaks:
  • Description/Symptoms: Leaks in the transmission fluid lines or seals can lead to low fluid levels and transmission slipping.
  • Solution: Repair of the leak and replacement of the transmission fluid.
  • Estimated Cost to Fix: $300 - $600

6-Speed Automatic

• TCM Failure:
  • Description/Symptoms: A faulty transmission control module (TCM) can cause the transmission to shift erratically or fail to shift altogether.
  • Solution: Replacement of the TCM.
  • Estimated Cost to Fix: $500 - $1,000+

Suspension

• Strut Mount Bearing Failure:
  • Description/Symptoms: Worn strut mount bearings can cause clunking or grinding noises when turning or going over bumps.
  • Solution: Replacement of the strut mount bearings.
  • Estimated Cost to Fix: $300 - $600

Electrical

• Battery Drain:
  • Description/Symptoms: Electrical components left on or a faulty alternator can drain the battery and cause the vehicle to fail to start.
  • Solution: Inspection of the electrical system and replacement of any faulty components.
  • Estimated Cost to Fix: $200 - $600

Exterior

• • No Issues Found*

Interior

• HVAC Blower Motor Failure:
  • Description/Symptoms: A faulty HVAC blower motor can cause the climate control system to fail to blow air.
  • Solution: Replacement of the HVAC blower motor.
  • Estimated Cost to Fix: $200 - $400
• Dashboard Cracking:
  • Description/Symptoms: Cracks may develop on the dashboard, particularly in the area around the passenger airbag.
  • Solution: Replacement of the dashboard.
  • Estimated Cost to Fix: $500 - $1,000+

Summary

While the 2004 Volvo S60 is generally a reliable and well-built vehicle, it has been reported to have some common issues. The most severe and expensive issue is the turbocharger failure on the 2.5-liter turbocharged inline-5 engine (218 HP). Other issues, such as the intake manifold failure on the 2.4-liter naturally aspirated inline-5 engine and the TCM failure on the 6-speed automatic transmission, can also be costly to repair. However, many of the other issues, such as the suspension issues and the interior issues, are relatively minor and less expensive to fix.