Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Volvo S60 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2002 Volvo S60. While driving at various speeds, there was an unusual odor of fuel. The contact discovered fuel leaking from the rear passenger side of the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel tank fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure and the VIN was not included in NHTSA campaign number: 09V483000 (fuel system,gasoline). The approximate failure mileage was 110,000.
Tl* the contact owns a 2002 Volvo S60. While driving at 45 MPH, a fuel odor emitted into the vehicle. In addition, the check engine warning light illuminated. The vehicle was taken to an independent mechanic. The technician diagnosed that the fuel pump was leaking. 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 106,539. The VIN was unavailable.
Tl contact owns a 2002 Volvo S60. The contact stated that while driving at various speeds, there was an extremely strong odor of fuel. The failure recurred numerous times. The vehicle was taken to a dealer where it was diagnosed that the fuel tank was leaking and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The VIN was not included in NHTSA campaign number: 09V483000 (fuel system, gasoline). The failure mileage was 150,830.
Posible taskata recall air bag light on/engine missing bad/tranmission shift fast and hard-sun roof don't works had tune-up done change turbo charger replaced/replaced trollder body-replace the radiator between and A/C evaporator that connect from turbo and troller body rough idleing whild starting and driving on the city streets. I would ask the power train and the speed control to include the electrical system be reviewed for service and any unknown or other.
Tl* the contact owns a 2002 Volvo S60. While driving various speeds, there was an abnormal fuel odor coming from the vehicle. The contact observed that the fuel pump module was leaking. The contact also observed that the instrument panel did not display the vehicle mileage. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage was 140,000.
Tl* the contact owns a 2002 Volvo S60. The contact stated that a strong odor of fuel fumes emitted in and around the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump was leaking. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 107,000. Updated 09/18/15
Tl* the contact owns a 2002 Volvo S60. While driving, the contact noticed an abnormal odor of fuel inside the vehicle. The vehicle was towed to a local dealer (valenti Volvo cars of watertown located at 105 commercial st watertown, ct 06795), but was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 171,000.
Tl* the contact owns a 2002 Volvo S60. The contact smelled a fuel odor inside and outside of the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump was fractured. The vehicle was not repaired. The dealer and manufacturer were not notified of the failure. The failure mileage was approximately 134,000.
Tl* the contact owns a 2002 Volvo S60. The contact stated that without warning fuel started leaking from the fuel tank. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 200,100.
I've had my car all of 4 months and I started to notice when it got really hot outside (summer) and when I went to start my car it would stall as if it was having a hard time starting up. Long story short I take it in to the dealer, they run a diagnostics test an tell me there is a crack in my fuel pump. I currently live in pennsylvania which is not one of the states listed for the fuel pump recall. I highly believe my car had a defective fuel pump because in the spring time, when it wasn't so hot my car was running fine. The Volvo dealer ship charged me $98.11/hr to run a diagnostics test which came to $102.83. Then on top of that they charged me $795 + tax for the parts and labor to replace my fuel pump after finding there was a crack in it. …
Related recalls
Fuel system, gasoline › Delivery › Fuel pump
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,…
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.
Fuel system, gasoline › Delivery › Fuel pump
On certain vehicles originally sold in or currently registered in the states of arizona and nevada, due to the combination of fuel quality and climate conditions, the fuel pump May, in certain cases, experience a reduced functionality. The most common symptoms would be fuel odor.
Remedy: Dealers will replace the fuel pump free of charge. The recall began on July 10, 2007. Owners May contact Volvo at 1-800-458-1552.
Fuel System complaints in other S60 years
Frequently asked questions
How common are fuel system problems on the 2002 Volvo S60?
NHTSA has 69 complaints about the fuel & propulsion system of the 2002 Volvo S60, 37% of the model year's 186 complaints. The component named most often is delivery › fuel pump (17 mentions).
Is there a recall for 2002 Volvo S60 fuel system problems?
Yes — NHTSA recall 09V-483 (fuel pump, Dec 18, 2009); NHTSA recall 07V-152 (fuel pump, Apr 5, 2007). Recall repairs are free at authorized dealers.
At what mileage do 2002 Volvo S60 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 108,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 1 injury to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.