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 2004 Volvo S60 owners, lightly cleaned up (personal details are redacted by NHTSA).
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 [redacted] 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. …
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.
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.
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.
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. …
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. …
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.
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?
Tl 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.
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 volvos 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.
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 complaints in other S60 years
Frequently asked questions
How common are fuel system problems on the 2004 Volvo S60?
NHTSA has 55 complaints about the fuel & propulsion system of the 2004 Volvo S60, 28% of the model year's 198 complaints. The component named most often is delivery › fuel pump (6 mentions).
Is there a recall for 2004 Volvo S60 fuel system problems?
Yes — NHTSA recall 09V-483 (fuel pump, Dec 18, 2009). Recall repairs are free at authorized dealers.
At what mileage do 2004 Volvo S60 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 91,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 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.