VolvoS602004Overview/volvo/s60/2004/base/

2004 Volvo S60

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 S60.

Body PASSENGER CARTransmission Automatic 5-spd

The 2004 Volvo S60 is a midsize passenger car built on Volvo’s early‑2000s platform and equipped with a six‑liter oil capacity powertrain that runs on 5W‑30 or 10W‑30 API‑rated oil, paired with a smooth‑shifting five‑speed automatic transmission and delivering an EPA rating of 18 mpg city, 25 mpg highway and 20 mpg combined. While its mechanical layout is solid, the model generated 198 owner complaints overall, with the most frequent issue centered on engine and engine‑cooling components and it was subject to six manufacturer recalls. Within the broader 2000‑2018 S60 complaint record, 2004 falls after the peak complaint year of 2001 (238 reports) and well before the minimal 2000 figure (one report), indicating a moderate reliability standing for its generation.

Model year202520242023202220212020201920182004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity6.1 qtOEM · verified
Engine oil type5W-30 / 10W-30 APIOEM · verified
Lug nut torque103 ft-lbsOEM · verified
EPA fuel economy18/25/20 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 48 · 600 CCA battery, OE oil filter 1275810. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 48 · 600 CCAOEM · verified
Tire size195-65HR15OEM · verified
Wheel / rim6.5, 7.0 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter1275810
Engine air filter8671488 alt 8649788
Fuel filter30620512 alt 32242189
Battery30772211 alt 30772221
Front wiper blades30784428 alt 30655498
Thermostat30637216 alt 31293699
Cabin air filter30630754 alt 30630752

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 5-spd

Dimensions & weight NHTSA vPIC

Overall length181.1 in
Overall width70.9 in
Overall height56.3 in
Wheelbase107.1 in
Curb weight3175 lb
Track (front / rear)61 / 61 in
Weight distribution (front / rear)59/41

Ratings & economy EPA / vPIC

EPA city / highway / combined18 / 25 / 20 mpg
Drivetrain4-Wheel or All-Wheel Drive
Passenger volume94 cu ft
Cargo volume14 cu ft
Recommended fuelPremium Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the S60 of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

5.5–5.8 sec0–60 mph (tested)quickest 5.50 sec — 2004 R
YearTrim / engine0–60¼ mileHPDrivetrain
2004R 2.5L Turbo I-55.50 sec14.00 sec300 hpAWD
2004R 2.5L Turbo I-55.80 sec14.40 sec300 hpAWD
2005R 2.5L Turbo I-56.40 sec14.60 sec300 hpAWD
2002T5 2.3L Turbo I-57.00 sec15.50 sec247 hpFWD
20022.4T 2.4L Turbo I-57.40 sec15.80 sec197 hpAWD
20022.4T 2.4L Turbo I-57.40 sec15.70 sec197 hpAWD
20022.4T 2.4L Turbo I-57.40 sec15.70 sec197 hpAWD
2006R 2.5L Turbo I-56.10 sec14.40 sec300 hpAWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 6.1 qt of 5W-30 / 10W-30 API engine oil, DOT 4 brake fluid. Torque lug nuts to 103 ft-lbs, the oil drain plug to 28.0 ft-lbs. The firing order is 1-2-4-5-3.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity7.0-7.5
Brake FluidDOT 4
Engine Oil5W-30 · API · 10W-30
Engine Oil Capacity6.1 qt
Engine Oil5W-30 · API · 10W-30
Engine Oil Capacity5.5 qt
Manual Transmission FluidVolvo part number 1161745

Engine torques

Crankshaft Pulley and/or Damper BoltsCenter bolts, step 1: 133 ft-lbs
Crankshaft Pulley and/or Damper Bolts133 ft-lbs
Intake Manifold to Engine Bolts15 ft-lbs
Exhaust Manifold to Cylinder Head Bolts19 ft-lbs
Engine Oil Pan Drain Plug24.0 ft-lbs
Engine Oil Pan Drain Plug28.0 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs7 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs4 ft-lbs

Chassis torques

Lug Nuts103 ft-lbs
Transfer Case Fill Plug27.0 ft-lbs
Transfer Case Drain Plug27.0 ft-lbs

Ignition

Cylinder Firing Order1-2-4-5-3
Curb Idle Speed (No Load)850 rpm
Curb Idle Speed Variance (No Load)50 rpm
Ignition Coil Primary Resistance.50-1.5 ohms
Ignition Coil Secondary Resistance8000-9000 ohms
Ignition Coil Primary Resistance.05-1.5 ohms
Ignition Coil Secondary Resistance8000-9000 ohms
Spark Plug Gap0.020-0.030 in

Battery & A/C

RefrigerantR134a
Refrigerant Capacity2.20 lbs
Oil TypeVolvo part No. 1161 627-3
Oil Capacity2.37 oz
Standard BCI Group Number48
Standard BCI Cranking Performance600 cca
Optional BCI Group Number49
Optional BCI Cranking Performance800 cca

Service checks

Pressure Test---- psi
Radiator Cap Pressure Relief---- psi
Thermostat Opening Temperature----- °F
Injector Primary Resistance12 ohms

Brakes

Torque Caliper to Bracket22 ft-lbs
Torque to Knuckle74 ft-lbs / 44 ft-lbs
Minimum Pad ThicknessFront: 0.079; Rear: 0.079 in
Rotor Runout Limit0.0016 in
Rotor Minimum Machining0.937 in / 1.016 in / 0.421 in
Rotor Discard at or Under0.906 in / 0.984 in / 0.394 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 9015 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs., Step 2: 18 ft. lbs., Step 3: 10011 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
111 ft. lbs, Step 2: 18 ft. lbs, Step 3: 10011 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs., Step 2: 6533 ft. lbs
Engine Flywheel Bolts — tightening sequence 1 stages
133 ft. lbs. Step 2: 6533 ft. lbs
Main Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 33 ft. lbs.; M8 Bolts: 18 ft. lbs.; M7 Bolts: 13 ft. lbs.; M10 Bolts: 90 degrees15 ft. lbs
Main Bearings — tightening sequence 1 stages
115 ft. lbs, Step 2: 33 ft. lbs.; M8 Bolts: 18 ft. lbs.; M7 Bolts: 13 ft. lbs.; M10 Bolts: 90 degrees15 ft. lbs
Main Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 33 ft. lbs.; M8 Bolts: 18 ft. lbs.; M7 Bolts: 13 ft. lbs.; M10 Bolts: 90 degrees15 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant every 15,000 mi. The big-interval services (every 15,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 miBrake Linings (inspect) · Brake Rotor (inspect) · CV Joint Boot (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Engine Oil (drain & refill)
Every 15,000 miBattery (inspect) · Brake Hydraulic System (drain, refill & bleed) · Brake Shift Interlock Solenoid (inspect) · Cabin Air Filter (replace) · Door Hinge (lubricate) · Engine Coolant System (leak inspection)
Every 30,000 miBrake Line (inspect) · Fuel Line (inspect)
Every 37,500 miEngine Air Filter Element (replace)
Every 45,000 miPCV Hose (inspect)
At 60,000 miCV Joint Boot (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Exhaust System (Complete) (inspect) · Steering System (inspect) · Suspension System (inspect)
Every 60,000 miSpark Plugs (replace) · Timing Belt (inspect)
At 105,000 miDrive Belt (replace) · PCV Hose (inspect)
At 120,000 miFuel Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Volvo S60 sits in the middle of a first-generation arc that saw complaint volumes peak early—238 in 2001 and 189 in 2002—then decline to 123 in 2003 before rebounding to 198 in the target year. Recalls followed a similar downward trend from 9 in 2001–2002 to 7 in 2003 and 6 in 2004, while investigations dropped to zero after 2002, suggesting that the most serious systemic issues were addressed earlier. However, the 2004 model’s complaint count is the second-highest in the generation, driven primarily by engine and fuel system concerns, and it records 12 crash complaints and 12 fire complaints—figures that stand out against the generally lower incident rates of later years. This places the 2004 S60 in a transitional phase where recall activity had eased but owner-reported problems, including safety-related ones, remained elevated. The data does not specify root causes for these complaints, but the pattern indicates that a 2004 purchase carries more risk than later first-generation models, which show a clear and sustained decline in complaints.

6
Open recalls
NHTSA campaigns
182
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
198
Owner complaints
12 involved a crash · 12 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 198 complaints on record, top 8 components.

Engine & Engine Cooling46
Fuel System, Gasoline20
Fuel/Propulsion System12
Engine11
Seats10
Electrical System9
Power Train9
Tires8

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 6 campaigns on record for this vehicle.

21V766000Air Bags:Frontal:Driver Side:Inflator ModuleReported 30/09/2021

Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure… Remedy: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at…

10V566000Equipment:Electrical:Navigational System(Global Positioning System)Reported 08/11/2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT. Remedy: 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…

Technical service bulletins NHTSA · verified

Showing 5 of 182 bulletins on record with NHTSA.

BulletinDateComponentSummary
35526.1.82026-04-23EngineThis is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform…
37809.1.12026-04-07Unknown Or OtherThis is a TJ text only - The purpose of this TJ is to be a master reference list to…
192452025-12-06Unknown Or OtherThis is a Technical Journal. Vehicle type and platform identification.
85012025-04-10Exterior LightingThis is a Technical Journal: Remote connection, BOMGAR application. Before joining a…
S103032025-02-21Unknown Or OtherVolvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific S60. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 S60 take?

6.1 qt of BELOW 86 degrees F: 5W-30 API, -4 degrees F TO 104 degrees F: 10W-30 API, per the factory manual.

Does the 2004 S60 have open recalls?

NHTSA lists 6 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the S60 get?

EPA figures are 18 city / 25 highway / 20 combined mpg.