Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

1.6

hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
106,042 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Volvo S60 fuel system problems

fuel system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Volvo S60:

Unsubscribe any time. We don't sell/share your email.

2004 Volvo S60 Owner Comments

problem #13

Oct 112016

S60

  • 140,000 miles

A D V E R T I S E M E N T S

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

- League City, TX, USA

problem #12

Jun 182016

S60

  • miles
Car stalled whilst breaking

- Washington, DC, USA

problem #11

Jan 062016

S60

  • miles
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.

- Arlington, VA, USA

problem #10

Aug 152015

S60

  • 140,000 miles

A D V E R T I S E M E N T S

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.

- Bellevue, WI, USA

problem #9

Oct 312015

S60

  • 150,000 miles
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 NHTSA campaign number: 07V226000 (engine and engine cooling). The manufacturer was not notified of the failure. The approximate failure mileage was 150,000.

- Whittier, CA, USA

Search CarComplaints.com for these popular complaint phrases...

problem #8

Sep 102015

S60

  • 170,000 miles
The contact owns a 2004 Volvo S60. The contact stated that when turning the key into the ignition switch, the vehicle failed to start. The vehicle was towed to an independent mechanic who diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The vehicle was not included in NHTSA campaign number: 09V483000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 170,000.

- Kaufman, TX, USA

problem #7

Mar 242014

S60 5-cyl

  • 181,150 miles

A D V E R T I S E M E N T S

March 2014: I was travelling on a divided highway at 55 mph and the car stalled. Mechanic stated it was the fuel pump. Mar 2015 : this same event occurred again.

- Ocean Springs, MS, USA

problem #6

Dec 192014

S60

  • 97,000 miles
The contact owns a 2004 Volvo S60. The contact stated that while parked, the vehicle was leaking a large amount of fuel. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The VIN was unavailable. The failure mileage was 97,000.

- Clarefield, UT, USA

problem #5

Feb 062014

S60

  • 127,000 miles
The contact owns a 2004 Volvo S60. The contact stated that while driving a various speeds, the vehicle suddenly stalled. The vehicle was restarted and functioned normally. The vehicle was taken to the dealer who diagnosed that the fuel pressure sensor was faulty. The vehicle was not repaired. The manufacturer was not notified. The VIN was not available. The failure mileage was 127,000.

- Summerville, SC, USA

problem #4

Feb 262013

S60

  • 115,000 miles
Check engine light came on and car lost power while driving at highway speeds. It would not accelerate and displayed the message "reduced engine performance". dealer indicated it was a cracked intercooler hose and that caused the issue. It was replace and after about two months the same symptoms happened. It was then diagnosed as a bad electronic throttle body. That was replaced and the same symptoms happened within two months again. The car now does not accelerate more than 10 mph. The next diagnosis was to replace the complete engine wiring harness. The car is unsafe to drive because it stall or decelerate from highway speeds with no notice. It is very similar to a recall for model years up to 2002.

- Spencerport, NY, USA

problem #3

Jun 102013

S60

  • 56,293 miles

A D V E R T I S E M E N T S

The car had fuel pump replaced on 06/30/11 and again (under parts warranty) after being towed on 05/14/13. On June 10, 2013 the car had to be towed to dealer again with fuel supply issues. After much analysis, it was concluded that the fuel tank needed to be replaced. The price quoted for the part was $2447 and labor $1400. The fuel pump apparently has an inner connector seal (or ring and clip) that is integral to the tank (cannot be replace separately) that was popping loose under pressure. After much debate with Volvo of North America, they got approval to give me the part at half price--still $1223 plus around $900 labor. In discussing this with the shop foreman, he had talked to Volvo regional people one the lookout for flaws. They were aware of this problem, and although it was rare it had happened on several occasions to metal talks that are 'California' specs. Although Volvo is aware of the problem, they have not notified owners or done a recall but are requiring those with the defective part to discover it and pay for repairs on their own. I think Volvo should refund my repair costs and notify other owners who have the same fuel tank.

- Arliington, VA, USA

problem #2

May 042013

S60

  • 116,000 miles
The contact owns a 2004 Volvo S60. The contact stated that the check engine warning light was illuminated as soon as the engine was started. The vehicle was taken to a certified mechanic, who advised the contact that the fuel pressure sensor needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 116,000.

- Orangerburg , NY, USA

problem #1

Sep 162012

S60

  • 86,100 miles
The contact owns a 2004 Volvo S60. The contact stated that while traveling 30 mph the instrument panel began to illuminate then the vehicle stalled. The vehicle was able to be restarted to proceed to the contact's destination. The vehicle was taken to a dealer where it was found that the fuel injector had failed. The manufacturer was contacted and informed the contact that the vehicle was not included in NHTSA campaign id number: 09V483000 (fuel system, gasoline: Delivery: Fuel pump). The failure and current mileage was 86,100.

- Buffalo, NY, USA

Not what you are looking for?