2004 Volvo S60
2004 Volvo S60
Overview
The 2004 Volvo S60, a premium compact executive sedan, is generally regarded as a solid vehicle with a reputation for safety and comfort. While it offers a refined driving experience, like any vehicle of its age, it has certain areas that have seen more reported issues than others. This analysis focuses on common mechanical and electrical concerns that owners have reported, excluding routine maintenance. Understanding these potential problem areas can help prospective buyers and current owners make informed decisions regarding maintenance and potential repairs for this Swedish luxury car.
Engine
2.4L Naturally Aspirated (B5244S2)
Oil Leaks
- Symptoms: Visible oil spots under the vehicle, burning oil smell, low oil level.
- Solution: Replacement of seals and gaskets (e.g., valve cover gasket, oil pan gasket).
- Cost: $300 - $700
PCV System Clog
- Symptoms: Rough idle, increased oil consumption, engine misfires, potential for oil leaks from seals.
- Solution: Cleaning or replacement of the Positive Crankcase Ventilation (PCV) system components.
- Cost: $200 - $500
2.5L Turbocharged (B5254T2)
Turbocharger Issues
- Symptoms: Loss of power, whistling noises from the engine bay, increased oil consumption, check engine light.
- Solution: Repair or replacement of the turbocharger unit.
- Cost: $1000 - $2500
PCV System Clog
- Symptoms: Rough idle, increased oil consumption, engine misfires, potential for oil leaks from seals.
- Solution: Cleaning or replacement of the Positive Crankcase Ventilation (PCV) system components.
- Cost: $200 - $500
2.3L Turbocharged (B5234T3 - T5)
Turbocharger Issues
- Symptoms: Loss of power, whistling noises from the engine bay, increased oil consumption, check engine light.
- Solution: Repair or replacement of the turbocharger unit.
- Cost: $1000 - $2500
PCV System Clog
- Symptoms: Rough idle, increased oil consumption, engine misfires, potential for oil leaks from seals.
- Solution: Cleaning or replacement of the Positive Crankcase Ventilation (PCV) system components.
- Cost: $200 - $500
Transmission
AW55-50SN Automatic (FWD/AWD)
Harsh Shifting / Slipping
- Symptoms: Jerky gear changes, delayed engagement, slipping between gears, transmission warning light.
- Solution: Transmission fluid flush and filter change, solenoid replacement, or full transmission rebuild.
- Cost: $400 - $3000+
Transmission Control Module (TCM) Failure
- Symptoms: Erratic shifting behavior, transmission stuck in limp mode, no communication with TCM.
- Solution: Replacement of the Transmission Control Module.
- Cost: $500 - $1000
M56 Manual (FWD)
Clutch Wear
- Symptoms: Slipping clutch, difficulty engaging gears, burning smell.
- Solution: Clutch kit replacement (clutch disc, pressure plate, release bearing).
- Cost: $600 - $1200
Suspension
Standard Chassis
Worn Control Arm Bushings
- Symptoms: Clunking noises over bumps, vague steering feel, uneven tire wear.
- Solution: Replacement of front control arm bushings or the entire control arm assembly.
- Cost: $300 - $600
Worn Struts/Shocks
- Symptoms: Bouncy ride, excessive body roll, reduced handling performance.
- Solution: Replacement of front and/or rear struts and shocks.
- Cost: $400 - $800
Electrical
Body Control Module (BCM)
BCM Malfunctions
- Symptoms: Intermittent issues with power windows, locks, lights, or dashboard warning lights.
- Solution: Diagnosis and potential reprogramming or replacement of the BCM.
- Cost: $500 - $1200
ABS Module
ABS Module Failure
- Symptoms: ABS warning light illuminated, loss of ABS function.
- Solution: Repair or replacement of the ABS control module.
- Cost: $600 - $1500
CEM Module
CEM Water Ingress
- Symptoms: Various electrical gremlins, random warning lights, non-functional accessories.
- Solution: Sealing the sunroof drains and repairing/replacing the Central Electronic Module (CEM).
- Cost: $400 - $1000
Exterior
Standard Chassis
No Major Issues
- Symptoms: No widespread issues reported.
- Solution: No widespread issues reported.
- Cost: N/A
Interior
Standard Interior
No Major Issues
- Symptoms: No widespread issues reported.
- Solution: No widespread issues reported.
- Cost: N/A
Summary Verdict
The 2004 Volvo S60 is a well-built car, but like many vehicles from this era, it can develop specific issues. Common concerns revolve around the engine’s PCV system and potential oil leaks, especially on the naturally aspirated engines. Turbocharged models may face turbocharger wear. Automatic transmissions, particularly the AW55-50SN, are known for potential harsh shifting or solenoid issues, requiring diligent maintenance. Electrical gremlins, often linked to the BCM, ABS module, or CEM module (especially due to water ingress), are also reported. Suspension components like control arm bushings and struts can wear over time. Despite these potential issues, with proper maintenance and addressing problems promptly, the S60 can remain a reliable and enjoyable vehicle.