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2004 Volvo S60 fuel system problems

55 complaints (28% of all complaints for this car). Typical mileage when it fails: 91,000. 1 crash reported.

owner complaints
55
of this car's complaints
28%
typical mileage
91,000
crashes
1
recalls
1

Which part fails

  • Delivery: fuel pump
    6
  • Fuel injection system: fuel rail
    1
  • Fuel injection system
    1

At what mileage

Complaints by mileage at the time of the problem.

0k-25k
25k-50k
50k-75k
75k-100k
100k-125k
125k-150k
150k-175k
175k-200k
200k+

Volvo S60 fuel system problems in other years

2001200520152024

Specific symptoms reported on the 2004 Volvo S60 fuel system

Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.

Fuel pump 15

Related recalls

Fuel system, gasoline: delivery: fuel pumpReported December 18, 2009 · 158,733 vehicles affected
What is wrong
Volvo is recalling certain model year 2001-2005 s80, model year 2001-2004 v70, s60, xc70 and model year 2003-2005 xc90 vehicles sold in or registered in the states of alabama, arizona, arkansas, california, florida, georgia, hawaii, kentucky, louisiana, mississippi, nevada, new mexico, north carolina, oklahoma, south carolina, tennessee, texas, utah, virginia and the u.s. Territories. When exposed to certain environmental conditions (hot climate and temperature cycling) over time and in combination with varying fuel quality, the fuel pump can develop cracks in the fuel pump flange.
Risk
If the condition occurs vehicle owners may notice fuel smell and/or fuel leak which, in the presence of an ignition source, could result in a fire.
Remedy
Dealers will inspect the fuel pump installed in the vehicle, and if necessary replace the fuel pump with a part of a modified design. This service will be performed free of charge. The safety recall began on january 15, 2010. Owners may contact volvo at 1‑800‑458‑1552.

Recall number 09V483000 · Recall details

What 2004 Volvo S60 owners say

Most recent owner complaints, unedited.

Filed Nov 30, 2022 · Fuel system · VA

Starting Sunday November 27 my car started dripping gasoline on the floor, on the driver side near the rear wheel. Immediately I took it to Volvo dealer Wynne in Hampton, VA. The service specialist told me there was not any existing recall for that issue and let me go. That night I put under the leak a flat pan. That night I collected one gallon in about 8 hours. I called Volvo cars USA [XXX] explained me the car have been fixed for the campaign #09V483000 in September 14, 2010. I own the car since 2015. I asked her if the recall should be possible to do it again at no cost for me, because it falls under Safety due to the fact the car may get in fire due to the leak of gas. She asked me to go back again to Wynne Volvo dealer and tell to the service specialist that I talked to them and if they wouldn't repair my car I could open a case with Volvo Cars USA. The service specialist told me I could leave the car for inspection, but I would be responsible for at least $180 to get and estimate, but never said that they would fix it under the safety recall number 09V483000 for vehicles sold or registered in the states with hot climate like Virginia. The recall started in January 15, 2010. It covers the fuel pump that can develop cracks in the fuel pump flange. The technician said the repair they did under the recall was replacing an O-Ring gasket only not the fuel pump. The person I talked to in Service is [XXX] with Title Service Advisor. Phone number [XXX]. I called again today Wednesday November 30, 2022 to Volvo Cars USA they said they can not promise to wave the repair because they need first that I pay $180 for a car diagnostic of the issue. They would probably accept to pay part of the total charge but they would be doing it at good will. I don't have $180 to pay upfront for a safety recall that it didn't last but only 12 years. The Safety recall is valid as long as the car is in service, it doesn't matter if I am or not the first owner. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)

Filed Oct 21, 2021 · Airbags, Fuel system · CA

Recall airbags- fuel gauge goes up and down never registers correctly

Filed Oct 17, 2017 · Engine, Fuel system · CA

In stop and go traffic, my foot was on the brake to slow down. I took my foot off the brake and stepped on the accelerator as traffic moved again, there was no response to my foot on the gas pedal. The fuel tank, which I had just filled 10 miles before, showed as empty on the fuel gage. I was very, very slowly rolling forward with residual momentum and my steering wasn't working. There was just enough play in the wheel and forward momentum to aim and arrive at the shoulder of the highway. This was on rte 156 in monterey county, california, where very dangerous accidents happen all the time. Car had to be towed and the dealership has been unable to replicate failure. It was outrageously dangerous and I was alone with my 11-year-old child. So frightening!!!

Filed Sep 16, 2017 · Fuel system · 2 miles · IN

Engine stalls....multiple times

Filed Jul 12, 2017 · Fuel system, Steering · MD

I just recently went to a dealer for a gas fuel leak. They noticed a crack in the holder. The mechanic also asked me to check for a recall before fixing due to this being a common problem with some volvos. I am also noticing there is a powersteering leakage somewhere because im constantly putting in powersteering. Please take my complaint in consideration due to it being life threating and I have children who I have to carry around in that vehicle. If its a defective equitment on volvo im asking for immediate replacement. For safety

Filed Oct 11, 2016 · Fuel system · 140,000 miles · TX

Gasoline fill overflows frequently when putting in fuel, regardless of amount of fuel already in the tank.

Filed Jun 18, 2016 · Engine, Fuel system · DC

Car stalled whilst breaking

Filed Jan 7, 2016 · Fuel system · VA

Fuel pump leaked. Smell gas. Scared it may catch fire. Expensive repair. Volvo is refusing to honor recall because (1) vehicle purchased in nj (though has spent life in va) and (2) work done at non-volvo mechanic. Due to the severity of the issue, I took it to the nearest mechanic rather than risk driving it to dealer and having it catch fire.

Filed Dec 7, 2015 · Engine, Fuel system · 140,000 miles · WI

Tl* the contact owns a 2004 volvo s60. The contact stated that while driving at various speeds, the vehicle stalled. The contact was able to restart the vehicle. The check engine warning light illuminated. The failure recurred on numerous occasions. The vehicle was taken to an independent mechanic who diagnosed that the fuel rail pressure sensor needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 140,000.

Filed Dec 1, 2015 · Fuel system · 150,000 miles · CA

Tl* the contact owns a 2004 volvo s60. While driving 65 MPH, the vehicle stalled. The contact was able to restart the vehicle. The contact stated that the failure recurred several times. The vehicle was taken to be diagnosed at the dealer. The contact was informed that the fuel pressure sensor needed to be replaced. The vehicle was not repaired. The vehicle was not included in the federal safety agency campaign number: 07v226000 (engine and engine cooling). The manufacturer was not notified of the failure. The approximate failure mileage was 150,000.

Questions about the 2004 Volvo S60 fuel system

Does the 2004 Volvo S60 have fuel system problems?

Owners have filed 55 complaints about the fuel system of the 2004 Volvo S60, 28% of all its complaints.

At what mileage do 2004 Volvo S60 fuel system problems start?

The typical (median) mileage in owner complaints is 91,000 miles.

Was there a recall on the 2004 Volvo S60 fuel system?

Yes, 1 recall: 09V483000. Check your VIN to see if your car still needs the free repair.

What year does the Volvo S60 have the most fuel system problems?

The Volvo S60 model years with the most fuel system complaints are 2001 (88 complaints), 2002 (69 complaints) and 2004 (55 complaints).

Is there a class action lawsuit over the Volvo S60?

Yes. New class action says Volvo's Google-based infotainment screens freeze and take climate and rearview camera with them (November 9, 2026).

Other 2004 Volvo S60 problems

Engine 85Electrical 21Seats 12Transmission 12Acceleration 11Airbags 9Brakes 9Steering 9Tires 9Lights 7Body 4Suspension 3Locks 2Seat belts 2Visibility 2Driver assistance 1

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