hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
94,463 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

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2004 Volvo S60 Owner Comments (Page 1 of 2)

problem #22

Sep 032014

S60 5-cyl

  • 155,000 miles


My car was dying on the highway or on a regular street road. Ended up being the fuel pressure sensor which is on the recall list but didn't come up for my VIN. I was dealing with this for 6 months or so and it was very dangerous. I don't understand why my car isn't on the recall list. Any help is appreciated. [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Hazelwood, MO, USA

problem #21

Oct 152014


  • 130,000 miles
The contact owns a 2004 Volvo S60. The contact stated that while driving approximately 40 mph, the vehicle would lose power and exhibit a sudden increase in engine rpms before the vehicle accelerated. In addition, the check engine warning light illuminated intermittently. The dealer diagnosed that the fuel pressure sensor needed to be replaced. The vehicle had not been repaired. The manufacturer was notified of failure. The VIN was unavailable. The approximate failure mileage was 130,000.

- Popular Grove, IL, USA

problem #20

Jul 162014

S60 5-cyl

  • 203,000 miles
Loss acceleration in the vehicle on the highway at 60 mph. The car would not speed up and continue to slow down but never came to a full stop. I was not able to go pass 40 mph in the car and acceleration was slow. First time it happen, the dealer said throttle body and oil collection system needed to be replaced. I replaced both. It happens again, took it to a different person, the mechanic said fuel control needed to be replaced. I replaced that. It happen the third time and took it to dealer and he informed me the spark plugs. I replaced that. Now, the problem is still happening.

- Chicago, IL, USA

problem #19

Mar 212014

S60 5-cyl

  • 112,329 miles


I had my car in for service at my local Volvo repair shop and one of the items I had them investigate was a fuel smell. They told me they found a crack at fuel pump sender rh side. They mentioned that they thought there was a recall for this since they have seen it several times before and that I should contact my Volvo dealer. I just looked online and found what they were talking about but it does not list the state where I purchased the vehicle and reside" I am the original owner. The repair shop did contact a local dealer for me and the dealer told them that there was not a recall? I guess I will contact some other local dealers this week and see what they say? seems like Colorado should have been added to this recall every state near us is part of it. If I cant get this repaired under the recall what should I do to make it happen"

- Golden, CO, USA

problem #18

May 022013

S60 5-cyl

  • 135,500 miles
Driving home after purchasing the car (yeah), I was turning into a parking lot, so my speed was descending and the car stalled. I wrote it off as my fault because it did not happen again until 3 months later. Within the past 3 weeks the car has stalled while in motion approx. 6 times. Volvo stated the recalled part for this issue was replaced in 2009. I notified the dealer and have a appointment for repair, at my expense because it was already replaced. Meanwhile I will not drive the car due to the lack of safety. Wish I would have researched the car model before purchase.

- Bernville, PA, USA

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problem #17

Jun 142013

S60 5-cyl

  • 103,000 miles
While driving 70 mph, car lost acceleration and stalled without warning. If I would have been rear ended going at this speed I could have lost my life. Check engine light came on and all codes are associated with the 181 recall. Called Volvo and Volvo stated that this VIN number was not part of the recall yet I am experiencing the same exact problem and have the same exact engine codes when running a diagnostics test associated with this recall.

- Apple Valley, MN, USA

problem #16

Jul 152011


  • 67,000 miles


The contact owns a 2004 Volvo S60. The contact stated that the vehicle would fail to accelerate when driving at various speeds. The contact also stated that the vehicle would intermittently stall during the failure. The vehicle was taken to an authorized dealer and an independent repair shop to have the failure diagnosed. The contact was informed that the failure was due to the fuel pressure system. The contact was also informed that the vehicle was not included in the recall associated with NHTSA campaign id number 09V483000 (fuel system, gasoline:delivery:fuel pump). The failure mileage was 67,000.

- Mount Pleasant, SC, USA

problem #15

Oct 042011

S60 4-cyl

  • 52,860 miles
I own a 2004 Volvo S60. I recently found out that there is a recall on my vehicle after my mechanic told me my check engine light was due to this recall. Volvo says there is no such recall at first, but upon calling the customer service number I found out that there is. However, they say it is VIN specific and that mine is not covered. My mechanic says that this needs to be taken care of, for this problem can cause my engine to stall out at anytime and cause my steering wheel to jerk around on the highway. To me, this is a huge problem, sounds like that it could potentially kill me on the road. How can something that can be this potentially dangerous not be Volvo responsibility to fix? just because my VIN number is different does not mean the problem is any less serious, though Volvo seems to think it is.

- Agawam, MA, USA

problem #14

Jun 012011


  • 112,000 miles
The contact owns a 2004 Volvo S60. The contact stated that when driving at various speeds, she noticed that there was an odor of gasoline. A fuel leak was also discovered. The vehicle was taken to the dealer where they advised her that the seam of the fuel tank was rotted and needed to be replaced. The entire fuel tank was replcaced. The manufacturer was not contacted. The failure mileage was approximately 112,000.

- Wantagh, NY, USA

problem #13

Jun 182011


  • 72,600 miles
The contact owns a 2004 Volvo S60. While driving 75 mph, the contact stated that she applied pressure to the accelerator pedal; however, she was unable to accelerate when she noticed that the check engine warning light illuminated. The dealer had not been notified. The manufacturer was aware of the failure. The vehicle was taken to a private mechanic who inspected the vehicle and informed the contact that the fuel regulator pressure sensor had failed and needed to be replaced. No repairs were performed. The current mileage was 73,000. The approximate failure mileage was 72,600.

- Greensboro, NC, USA

problem #12

Dec 132010

S60 5-cyl

  • 75,000 miles


The engine light came on in my 2004 Volvo S60R. The car would loose acceleration and also stalled. Volvo said it was the fuel pressure sensor and that it had been recalled by Volvo- recall # 07V226000. But the VIN # of my car was not included in the recall. It was the same part that was recalled on other 2004 S60S. Why not on the R as well?

- Lake Villa, IL, USA

problem #11

Oct 062010

S60 5-cyl

  • 34,493 miles
Took vehicle to a Volvo dealership for a regularly scheduled oil change. The service advisor reported that the fuel pressure sensor (fps) is a critical component, that it failed and needed to be replaced. He said that Volvo would pay 50% for the part and charge me the warranty labor rate. They would not tell me in advance the total cost. As I was leaving, another service advisor told a person over the telephone they needed a fuel pressure sensor and would get 50% off. A few days later a friend took her S40 to this dealer and was told she needed a fuel pressure sensor to fix her actual fuel system problem (it did not). The odds of a person learning about 3 Volvo needing fuel pressure sensor replacements in this manner seems phenomenal. As such, it appears that either: 1) Volvo's fuel pressure sensors have a high fault rate; 2) Volvo understated the cars to include in its recall campaign number R181; 3) cars included in the recall campaign are being charged for the repair; or 4) the question of how Volvo is / is not managing the dealer to determine if there is a high incidence of fuel pressure sensor failures on the cars being serviced during that time period and the reasons for those failed fuel pressure sensors. NHTSA should require Volvo to supply statistics and records (probably a simple Volvo database search) for all vehicles receiving new fuel pressure sensors and identify whether: 1) the repair was included in recall number R181; 2) the non-recall fps customer was charged for the repair; 3) the non-recall fps customer was not charged for the repair. And, for those vehicles, the NHTSA should require Volvo to provide the plant, production date, and chassis number. Running the report in model number and chassis number order (chronological order) of all cars with fps problem would likely aid the NHTSA in determining whether the extent of the fps problem and accuracy of the Volvo's recall campaign number R181.

- Lewisville, TX, USA

problem #10

Jun 152008


  • 80,000 miles
Purchased auto new. It would seem that I have had some of the same problems mentioned by others. Car stalling on highway at 65 miles per hour, twice, very scary. Pulled off and restarted. (fuel pressure sensor malfunction) seems there is a recall however when I inquired my VIN # was not included. Costly repair as must purchase part from dealer. Driver side head lamp, low beam, has been replaced so often lost track, over half a dozen times, is out now! have never replaced passenger side lamp! I point out the other S60's I see on the road with a headlamp light out to my kids as a game now.

- North Providence, RI, USA

problem #9

Oct 252010


  • 109,000 miles
The contact owns a 2004 Volvo S60. The contact stated that while driving approximately 10 mph, the vehicle stalled while the contact decelerated to make a turn. The vehicle was taken to an authorized dealer who stated that the fuel rail pressure sensor was defective. The vehicle had not been repaired. The failure mileage was approximately 109,000.

- Richmond, VA, USA

problem #8

Aug 012010


  • 60,000 miles
My car stalled twice at low speed, both times was able to re-start immediately. After the 2nd incident, the check engine light illuminated with a generic obd-II code of P0192. Online research has found this code relates to the failure of the vehicle's fuel pressure sensor. Volvo has recall #R-181 in place but I am told by Volvo care that my car is excluded from eligibility for this recall based on the chassis number - despite having the same engine code (61) and experiencing the same issue as described in the Volvo recall notice. I have found a number of similar complaints on various website forums and even this (NHTSA) website. It would seem to me that Volvo may have to re-visit the criteria for how they determined which vehicles are affected by this faulty fuel pressure sensor. Having to pay $300+ out of pocket for a known faulty product is insulting.

- Townsend, DE, USA

problem #7

Aug 092010


  • 105,500 miles
1. vehicle stalled 2 times, last year and on 08/09/2010 while driving on highway. I was able to restart both time. The second time I was able to restart after 5 minutes and drive to the nearby the Volvo store dealership. 2. the dealership diagnosed the problem and determined the battery was the issue. However I see 2 recall campaign id numbers: 09V483000 and 07V226000 which may be the root cause of the problem. I talked to the service manager at the Volvo store dealership (1051 w. webster ave, winter park, fl 32789 - 407-628-0550) but the dealership won't look at it because they said my car is not shown up for recall in their Volvo database. 3. replace the battery.

- Orlando, FL, USA

problem #6

May 132010


  • 93,000 miles
The contact owns a 2004 Volvo S60. While turning on the vehicle, the contact noticed that the check engine light had illuminated on the instrument panel. The vehicle was taken to an authorized dealership where the contact was informed that the fuel pressure sensor was the cause for the light. The dealer reset the sensor. The light illuminated again so the vehicle was taken back to the dealership where the contact was informed that fuel sensor needed to be replaced. The vehicle had not been repaired at the time of the complaint. The current and failure mileages were approximately 93,000.

- Charlottesville, WA, USA

problem #5

Aug 102009


  • 76,678 miles
Certified previously owned vehicle stalled due to butterfly valve within throttle body not opening fast enough when going around a corner and too much load on the engine. Example: Exited freeway and was turning left while braking due to upcoming red light. The engine stalled in the middle of an intersection while the vehicle was in motion at approximately 10 mph. Lost steering and braking power. The problem was first noticed when making right turns and having to suddenly brake for a pedestrian, bicyclist, or other traffic hazard and the engine stalling or fluttering at much lower speeds. As it worsened over the course of a week it was ultimately the worst with the mid-intersection stall. At this point we were afraid to drive the vehicle for fear of crashing. Vehicle was purchased from a dealer as certified pre-owned 68,735 miles on 05/02/2008 and was taken to dealer for stalling at 76,678 miles on 08/15/2009. Dealer reported this as a maintenance issue not covered under warranty. Repairs for cleaning the throttle body, resetting valve, and installing new gaskets was $402.93. Vehicle originally purchased in southern California. Vehicle moved to Washington in February of 2009.

- Seattle, WA, USA

problem #4

Oct 092009


  • 64,230 miles
2004 Volvo S60 R AWD with less than 65,000 miles started leaking fuel that is running down the passenger side of the gas tank and there is a very strong pungent gas odor emitted from the passenger side of the rear of the vehicle. Took the car to Volvo of georgetown and local Volvo mechanic who both told me that the vehicle needed a new fuel pump but I was not covered under the S60 fuel pump recall a few years prior. Big safety hazard and concern!

- Austin, TX, USA

problem #3

Jul 022009


  • 77,000 miles
The contact owns a 2004 Volvo S60. While driving approximately 25 mph, there was no response when the accelerator pedal was depressed. Suddenly, the engine stalled. There were no warning indicators illuminated on the instrument panel. Roadside assistance was called to the scene and the vehicle was towed to an independent mechanic for inspection. The technician started the engine, but was unable to duplicate the failures. The vehicle was taken to an independent mechanic on a separate occasion for identical failures and the contact was informed that the fuel pressure sensor failed. The VIN was excluded from NHTSA campaign id number 07V226000 (engine and engine cooling), although the failures were identical. The vehicle was repaired at the contact's expense. The failure and current mileages were 77,000.

- St. Louis, MO, USA

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