2003 Volvo S80 Fuel system Problems

In Tank Fuel Pump, problem was leaking at top of pump @ the inlet at the outlet & return valve, crack in the plastic mold. Was giving off fumes, totally unhealthy and waitin for someone to light up a cigarette for a total car explosion and death for all occupants. I have replaced the pump myself. Local Dealer wanted 1100 plus to replace out of my budget This in my view it should have been done by recall, local Jim Volvo of Portland, Oregon said no, out of warranty period. I disagree, If unrepaired, I would have been risking me and my family or occupants in the vehicle at the time. There are still many of these cars and other models & years that I found my research on the web that has had this same problem. I have a 1998 Volvo s70 that appears to be developing the same issue. I had come to like my 2003 S80, it will be my last Volvo My cost so far About $150, and 1st pump I installed was defective, had to start over [XXX] [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11526377

Incident

Mar 15, 2023

Within a week of purchasing the vehicle from a dealer, I discovered that the fuel tank has a leak, so its currently unsafe to drive. I found out about the leak when I brought it to an independent mechanic for service. I see that other vehicles of this model and year had been recalled for fuel leaks, so I wanted to report the issue.

NHTSA ID

11419916

Incident

Jun 2, 2021

TL* THE CONTACT OWNS A 2003 VOLVO S80. THE CONTACT SMELLED FUEL INSIDE THE VEHICLE. IT WAS DIAGNOSED THAT THE FLANGE WAS CRACKED ON THE FUEL PUMP. THE MANUFACTURER WAS NOTIFIED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 112,000.

NHTSA ID

10849576

Incident

Feb 22, 2016

Mileage

112,000 mi

MY CAR SHOWS EXACT SYMPTOMS OF THE VEHICLES INVOLVED IN NHTSA RECALL # 09V483. RECALL INVOLVED CARS IN THE HOT WEATHER STATES OF US. AT THE TIME OF THE ORIGINAL RECALL I HAVE RESIDED IN THE MASSACHUSETTS WHICH WAS NOT INCLUDED IN THE INITIAL RECALL. I HAVE MOVED TO ARIZONA IN THE SUMMER OF 2010 AND NOW MY CAR IS SMELLING GAS AS RECALLED VEHICLES. TRIED TO CONTACT VOLVO DEALERS AND THY ARE STATING SINCE MY VIN IS NOT IN THE DATABASE OF RECALLED VEHICLES THEY WILL NOT PERFORM REPAIR ( UNLESS I WILL PAY FULL PRICE OF COURSE ). *TR

NHTSA ID

10521782

Incident

Jun 23, 2013

Mileage

101,500 mi

HI, JUST HAD TO HAVE MY FUEL PUMP REPLACED TO THE TUNE OF WELL OVER A THOUSAND DOLLARS. COST AND PROBLEM FALL IN TO THE "UNREAL" CATEGORY. HARD TO BELIEVE THAT SOMETHING AS SIMPLE AS A FUEL PUMP HAS EVOLVED INTO A PIECE OF EQUIPMENT THAT APPARENTLY AS COMPLICATED AS SOMETHING THAT IS VITAL TO THE LAUNCH OF THE SHUTTLE. OH FOR THE DAYS WHEN A FUEL PUMP WAS ACTIVATED BY THE CAM SHAFT, HELD ON TO THE ENGINE WITH TWO BOLTS, COST FIVE DOLLARS, TOOK ABOUT TEN MINUTES TO REPLACE AND SELDOM FAILED. ACCORDING TO THE STEALERSHIP THAT DID MY WORK, IN ORDER TO GET TO THE FUEL PUMP, THEY HAD TO REMOVE THE REAR SEAT TO GET TO THE FUEL PUMP? I HAVEN'T HAD TIME TO SURVEY THE TOTAL AMOUNT OF DAMAGE THEY DID IN DOING THIS, BUT DO KNOW THAT THE HEADLINER AND STEERING WHEEL ARE COVERED WITH GREASY HAND PRINTS AND AFTER THREE DAYS THERE IS STILL A STRONG ODOR OF GASOLINE IN THE CAR. MY VOLVO IS AN 03 S80 WITH ONLY 45,000 MILES ON IT. IS THIS TYPICAL OF VOLVO DEPENDABILITY AND EXCELLENCE? GUESS I'M GOING TO HAVE TO GO JAPANESE. COMMENTS PLEASE. *TR

NHTSA ID

10230258

Incident

Jun 2, 2008

Mileage

45,506 mi

AFTER PURCHASING A VOLVO S80 IN APRIL 2003 FROM VOLVO NORTH SCOTTSDALE, MY WIFE (WHO DRIVES THE CAR) BEGAN EXPERIENCING A FUEL INJECTION PROBLEM. EACH TIME THE CAR WAS ROUTINELY SERVICED AT VOLVO NORTH SCOTTSDALE, SHE COMPLAINED OF THE PROBLEM, BUT THE DEALER FAILED TO REPAIR IT. AFTER TIRING OF THE DETERIORATING SERVICE QUALITY AT VOLVO NORTH SCOTTSDALE, MY WIFE BEGAN HAVING THE CAR SERVICED AT POWELL VOLVO, TO WHOM SHE CONTINUED TO COMPLAIN OF THE FUEL INJECTION PROBLEM. THAT DEALER ALSO FAILED TO REPAIR THE PROBLEM. WHEN THE WARRANTY EXPIRED, MY WIFE HAD THE VEHICLE SERVICED AT AN INDEPENDENT MECHANIC, SWEDISH AUTO WERKS, TO WHOM SHE ALSO COMPLAINED OF THE FUEL INJECTION PROBLEM. AT THIS TIME, THE CAR HAD BEEN DRIVEN 35,990 MILES. BY THIS TIME, SHE WAS ALSO EXPERIENCING AN INTERMITTENT SLOW/LONG CRANK STARTING THE CAR, WHICH WAS THOUGHT TO BE DUE TO A FAILING BATTERY. SHE COMPLAINED OF THIS ALSO TO SWEDISH AUTO WERKS. SWEDISH AUTO WERKS DIAGNOSED THE CAUSES OF THE PROBLEM AS NOT ONLY A FAILING BATTERY BUT ALSO A CRACKED FUEL PUMP HOSE NIPPLE. IN ADDITION TO A NEW BATTERY, IT INSTALLED A NEW FUEL PUMP ASSEMBLY AT A COST OF $821.97. THE CAR NOW RUNS VERY WELL. IN A SUBSEQUENT CONVERSATION WITH ANOTHER VOLVO OWNER, MY WIFE LEARNED AND HAS SINCE CONFIRMED THAT THIS FUEL PUMP PROBLEM HAS BEEN RECURRENT WITH THE VOLVO S SERIES SINCE AL LEAST 2002-03 AND THAT VOLVO KNOWS OF IT. MY WIFE ALSO LEARNED THAT THERE HAS BEEN A "SILENT RECALL" PROMPTED BY THIS PROBLEM--I.E., IF THE PROBLEM IS RECOGNIZED BY A VOLVO DEALER, VOLVO WILL FIX IT AT NO COST TO THE OWNER. NEITHER VOLVO NORTH SCOTTSDALE NOR POWELL VOLVO IDENTIFIED THE PROBLEM DESPITE MY WIFE'S REPEATED COMPLAINTS TO THEM. BY OCTOBER 4, 2007 LETTER AND ATTACHED COPY OF THE REPAIR INVOICE TO VOLVO CUSTOMER CARE CENTER, I REQUESTED REIMBURSEMENT. IN REPLY, VOLVO DENIED MY REQUEST, STATING THAT THERE HAD BEEN NO RECALL. THE DATE BELOW IS WHEN THE REPAIR WAS MADE. *TR

NHTSA ID

10206798

Incident

Sep 20, 2007

Mileage

35,990 mi

RE: 2003, VOLVO S80. I HAD JUST PULLED INTO A PARKING SPACE AT MY PRESCHOOL SON'S SCHOOL, I WENT TO SHIFT GEARS AND TAKE MY FOOT OFF THE BRAKE AND MY CAR HAD A SUDDEN ACCELERTATION CAUSING ME TO BE WITHOUT CONTROL OF MY CAR FOR OVER 50 FEET, HITTING A TREE, 3 SHRUBS AND A 3000 LB. ROCK. MY PRESCHOOLER AND I SUSTAINED MINOR INJURIES BUT MY CAR IS TOTALLED. MY CAR IS IN AN AUTO BODY SHOP AWAITING INSURANCE APPROVAL FOR A TOTALLED CAR. MY SON IS TRAUMATIZED AND I WAS SHAKEN UP FOR DAYS. I AM CONCERNED THAT THERE WAS A MACHANICAL FAILURE BUT I HAVE NOT RECEIVED A CALL BACK FROM VOLVO ABOUT AN INVESTIGATION. I WOULD LIKE TO REQUEST A FORMAL INVESTIGATION INTO THIS.

NHTSA ID

10122130

Incident

May 20, 2005

DEAR [XXX]. ,HIS IS TO NOTIFY ABOUT THE FAILURE OF THE VEHICLE S80 ON THE HIGHWAY AND THE DIFFICULTY WE ARE FACING WITH THE DEALER THAT SOLD THE CAR TO US. I, [XXX] HAS BOUGHT THE CAR WITH WIN # [XXX], FROM DARRELL WALTRIP VOLVO IN FRANKLIN TN ON 11/01/03. ON 11/26/03 THE VEHICLE SUDDENLY STOPPED AND IT WAS TAKEN TO THE DEALER. AFTER A WEEK WE WERE TOLD THE GAS INDICATOR IS BROKEN. MY ATTEMPTS TO GET A WRITTEN REPORT ABOUT THE CAUSE FOR THE VEHICLE FAILURE HAVE BEEN UNSUCCESSFUL. THE EVENT WAS VERY TRAUMATIC TO MY WIFE WHO WAS DRIVING THE VEHICLE AT THAT TIME. SHE WAS 9 MONTHS PREGNANT AND DUE TO DELIVER THE FOLLOWING WEEK. WITH THE SHOCK SHE HAS GONE THROUGH SHE IS SCARED TO DRIVE THE VEHICLE. THE GENERAL MANAGER [XXX] RESPONSE WAS THAT " PEOPLE CAN HAVE SHOCK EVEN WITH A FLAT TYRE". WE APPRECIATE YOUR INTERVENTION AND RESPONSE IN THIS MATTER. *AK INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10051289

Incident

Nov 26, 2003

Mileage

834 mi