2004 Volvo S60 diesel: common problems and MOT failures

What goes wrong more than usual on a 2004 Volvo S60 diesel?

Parts flagged at MOT more often on the 2004 Volvo S60 diesel than on all cars registered in 2004.

• Suspension arm bushes and joints2× usual
  Volvo S60

  18.8% All 2004 cars

  9.3%

  Failed outright at MOT: 3.8%, against 2.1% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £120–£180 (one arm) ClickMechanic

  At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

• Sidelights1.8× usual
  Volvo S60

  11.5% All 2004 cars

  6.5%

  Failed outright at MOT: 9.6%, against 5.7% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £10–£80 our estimate

  At the viewing: Ask a friend to check every light while you work the switches: indicators, brake lights, fog lights and reversing lights.

• Handbrake performance2.6× usual
  Volvo S60

  3.4% All 2004 cars

  1.3%

  Failed outright at MOT: 3.4%, against 1.3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £80–£300 our estimate

  At the viewing: Pull the handbrake on a slope. It should hold the car within a few clicks.

• Side repeaters2× usual
  Volvo S60

  3.8% All 2004 cars

  1.9%

  Failed outright at MOT: 1.1%, against 1% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £10–£80 our estimate

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

Common 2004 Volvo S60 diesel MOT failures and advisories

The share of 2004 Volvo S60 diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  45% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Lights and electrics
  42% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Brakes
  37% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Tyres
  34% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  11% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Exhaust and emissions
  10% of testsRough price £100–£1,200

  At the viewing: Look for black soot in the tailpipe, listen for blowing from the exhaust and check for engine or DPF warning lights.

Questions to ask the seller before buying a 2004 Volvo S60 diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Any recent work on the suspension arm bushes and joints? (Flagged at MOT 2× as often on the 2004 Volvo S60 diesel as on other cars the same age.)
2. Any recent work on the sidelights? (Flagged at MOT 1.8× as often on the 2004 Volvo S60 diesel as on other cars the same age.)
3. Any recent work on the handbrake performance? (Flagged at MOT 2.6× as often on the 2004 Volvo S60 diesel as on other cars the same age.)
4. Can I see the service history and receipts for any big jobs?