2004 Volvo S60 Fuel system Problems

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)

NHTSA ID

11495569

Incident

Nov 27, 2022

RECALL AIRBAGS- FUEL GAUGE GOES UP AND DOWN NEVER REGISTERS CORRECTLY

NHTSA ID

11437725

Incident

Mar 20, 2020

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!!!

NHTSA ID

11034151

Incident

Oct 15, 2017

ENGINE STALLS....MULTIPLE TIMES

NHTSA ID

11023797

Incident

Sep 8, 2017

Mileage

2 mi

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

NHTSA ID

11004724

Incident

Jul 12, 2017

GASOLINE FILL OVERFLOWS FREQUENTLY WHEN PUTTING IN FUEL, REGARDLESS OF AMOUNT OF FUEL ALREADY IN THE TANK.

NHTSA ID

10915204

Incident

Oct 11, 2016

Mileage

140,000 mi

CAR STALLED WHILST BREAKING

NHTSA ID

10875002

Incident

Jun 18, 2016

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.

NHTSA ID

10818605

Incident

Jan 6, 2016

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.

NHTSA ID

10808882

Incident

Aug 15, 2015

Mileage

140,000 mi

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 NHTSA CAMPAIGN NUMBER: 07V226000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 150,000.

NHTSA ID

10807716

Incident

Oct 31, 2015

Mileage

150,000 mi

TL* 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.

NHTSA ID

10778030

Incident

Sep 10, 2015

Mileage

170,000 mi

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. *TR

NHTSA ID

10703247

Incident

Mar 24, 2014

Mileage

181,150 mi

TL* 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.

NHTSA ID

10667635

Incident

Dec 19, 2014

Mileage

97,000 mi

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). *TR

NHTSA ID

10654041

Incident

Sep 3, 2014

Mileage

155,000 mi

TL* 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.

NHTSA ID

10651726

Incident

Oct 15, 2014

Mileage

130,000 mi

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. *TR

NHTSA ID

10610925

Incident

Jul 16, 2014

Mileage

203,000 mi

TL* 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.

NHTSA ID

10588205

Incident

Feb 6, 2014

Mileage

127,000 mi

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? *TR

NHTSA ID

10574239

Incident

Mar 21, 2014

Mileage

112,329 mi

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. *TR

NHTSA ID

10536822

Incident

Feb 26, 2013

Mileage

115,000 mi

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. *TR

NHTSA ID

10531592

Incident

May 2, 2013

Mileage

135,500 mi

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. *TR

NHTSA ID

10521856

Incident

Jun 10, 2013

Mileage

56,293 mi

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. *TR

NHTSA ID

10520078

Incident

Jun 14, 2013

Mileage

103,000 mi

TL* 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.

NHTSA ID

10514563

Incident

May 4, 2013

Mileage

116,000 mi

TL* 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.

NHTSA ID

10480682

Incident

Sep 16, 2012

Mileage

86,100 mi

TL* 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.

NHTSA ID

10432885

Incident

Jul 15, 2011

Mileage

67,000 mi