VehicleVerdict

2004 Volvo S60 fuel system problems

The 2004 Volvo S60 has 55 fuel system complaints filed with NHTSA — 21% of the year's total, and up sharply from the prior model year.

55

Fuel System complaints

21%

Share of year

1

Crash-involved

1

Related recalls

Fuel System complaints by year

Related recalls

09V483000Fuel SystemDecember 18, 2009 · 158,733 units

Defect

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.

Consequence

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.

What owners report

ON SEPTEMBER 18 I WAS TRAVELING DOWN INTERSTATE 10 WHEN MY 2004 VOLVO S60 COMPLETELY STOPPED RUNNING WHILE GOING 70 MPH. I WAS UNABLE TO GET THE CAR OUT OF THE TRAFFIC (NO POWER TO DRIVE TO THE SHOULDER). MY CAR WAS COMPLETELY USELESS. I CALLED 911 AND ROADSIDE ASSISTANCE TO GET HELP BEFORE I WAS…

Complaint filed with NHTSA · Fuel System · September 18, 2006 · crash

Common questions

How many fuel system complaints does the 2004 Volvo S60 have?

NHTSA has 55 complaints about the 2004 Volvo S60 fuel system — 21% of all complaints filed for that model year.

Are there recalls for the 2004 Volvo S60 fuel system?

Yes — 1 NHTSA recall campaign for this model year is tied to the fuel system: 09V483000.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.