VolvoS802004Overview/volvo/s80/2004/base/

2004 Volvo S80

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 S80.

Body PASSENGER CARTransmission Automatic 5-spd

The 2004 Volvo S80 is a passenger car paired with a 5-speed automatic transmission and an EPA rating of 18 city, 25 highway, and 20 combined mpg, with maintenance centered around a 5.8-quart oil capacity using 5W-30 or 10W-30 API viscosity. Across the model's complaint history spanning 1999 through 2016, this model year sits well below the 2000 peak of 345 complaints, logging 50 total owner complaints with the Fuel/Propulsion System as the top complaint area and five recalls on record. That positions the 2004 S80 in a middle tier of the model's reliability arc — not as troubled as the earliest years, yet still carrying enough reported issues that researchers should weigh propulsion-related concerns when evaluating it.

Model year201620152014201320122011201020092004

Quick specs

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

Engine oil capacity5.8 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. Note the factory battery is now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. 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 size215-55HR16OEM · verified
Wheel / rim7 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter1275810
Engine air filter8649788 alt 9454647
Fuel filter30620512
Battery9459948 discontinued · alt 9459949
Front wiper blades30699740 alt 30699739
Thermostat272335 alt 270854
Cabin air filter30630752 alt 30630754

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 5-spd

Dimensions & weight NHTSA vPIC

Overall length189.8 in
Overall width72 in
Overall height57.1 in
Wheelbase109.8 in
Curb weight3492 lb
Track (front / rear)62.2 / 61.4 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 volume99 cu ft
Cargo volume15 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 S80 of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

7.7 sec0–60 mph (tested)quickest 7.70 sec — 2004 2.5T Sedan
YearTrim / engine0–60¼ mileHPDrivetrain
20042.5T Sedan 2.5L Turbo I-57.70 sec15.60 sec208 hpAWD
2002T6 75th Anniversary Edition Sedan 2.9L Twin-Turbo I-66.30 sec14.60 sec268 hpFWD
2007V8 Sedan 4.4L V85.70 sec14.40 sec311 hpAWD
1999T6 Sedan 2.8L Twin-Turbo I-66.80 sec15.20 sec268 hpFWD
1999T6 Sedan 2.8L Twin-Turbo I-67.10 sec15.50 sec268 hpFWD

Service quick specs OEM factory data

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

This engine holds 5.8 qt of 5W-30 / 10W-30 API engine oil, DOT 4 brake fluid. Torque lug nuts to 103 ft-lbs. The firing order is 1-5-3-6-2-4. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity7.0-8.0
Brake FluidDOT 4
Engine Oil5W-30 · API · 10W-30
Engine Oil Capacity5.8 qt
Engine Oil5W-30 · API · 10W-30
Engine Oil Capacity6.1 qt
Engine Oil5W-30 · API · 10W-30

Engine torques

Intake Manifold to Engine Bolts15 ft-lbs
Exhaust Manifold to Cylinder Head Bolts19 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs7 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs7 ft-lbs

Chassis torques

Lug Nuts103 ft-lbs
Transfer Case Fill Plug27.0 ft-lbs
Transfer Case Drain Plug27.0 ft-lbs
Front Wheel Hub26 ft-lbs

Ignition

Cylinder Firing Order1-2-4-5-3
Cylinder Firing Order1-5-3-6-2-4
Curb Idle Speed (No Load)650 rpm
Curb Idle Speed Variance (No Load)50 rpm
Spark Plug Gap0.027 in
Spark Plug Torque22.0 ft-lbs
Spark Plug Gap0.027 in
Spark Plug Torque22.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity2.20 lbs
Oil TypeVolvo part No. 1161 627-3
Oil Capacity6.08 oz
Standard BCI Group Number48
Standard BCI Cranking Performance600 cca
Optional BCI Group Number49
Optional BCI Cranking Performance800 cca

Service checks

Injector Primary Resistance12 ohms
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 / 0.002 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
Cylinder Head — tightening sequence 3 stages
115.0 ft. lbs.15 ft. lbs
244.0 ft. lbs.44 ft. lbs
3130 degrees130 degrees
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

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)
At 105,000 miDrive Belt (replace) · PCV Hose (inspect)
At 120,000 miFuel Filter (replace) · Timing Belt (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 Volvo S80 generation saw extreme federal complaint activity in its early years, peaking at 345 complaints in 2000 before dropping significantly to 45 by 2002. The 2004 model year sits at the tail end of this downward stabilization arc, registering 50 complaints—a slight increase from the 29 logged in 2003, but a vast improvement over the troubled 1999-2001 period. For the 2004 model, the data does not specify root causes, but the Fuel/Propulsion System leads the complaint areas with 13 reports, followed by Steering (5) and Engine & Engine Cooling (4). With zero federal investigations and 5 recalls, the 2004 S80 aligns with the broader generation's shift away from the severe scrutiny that marked the early models. Given its position in the generation's stabilization arc and manageable complaint volume compared to the earlier years, the 2004 model is a reasonably good year to buy, provided you prioritize a pre-purchase inspection of its fuel and steering systems.

5
Open recalls
NHTSA campaigns
190
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
50
Owner complaints
4 involved a crash · 0 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 50 complaints on record, top 8 components.

Fuel/Propulsion System13
Steering5
Engine & Engine Cooling4
Tires3
Suspension2
Electrical System2
Seat Belts2
Service Brakes, Hydraulic2

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 5 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 190 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 S80. 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 S80 take?

5.8 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 S80 have open recalls?

NHTSA lists 5 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the S80 get?

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