Six problems related to tank assembly have been reported for the 2001 Volvo S60. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2001 Volvo S60 based on all problems reported for the 2001 S60.
Fuel tank overflows before tank is full and spills fuel on drvier and ground. Happens constantly each time I try to fill the tank. Bought the vehicle with the problem, but I was not apprised by the previous owner. Checked the internet and the problem is very common among Volvo vehicles, especially this model. Volvo refuses to issue a recall and instead wants customers to pay for the repair.
Vehicle is hard to start, coupled with a strong fuel smell emitting from the fuel tank fill neck.
Strong fuel smell from rear of car and pump leaking at tank.
I bought my 2001 Volvo S60 n/a brand new at the end of 2001. Since up to about September of 2007, I had no problems with the vehicle except routine service. Then I noticed loud "clanging" and "metallic thumping" whenever I went over rough roads at any speed. Turns out that my control arm bushings (be they ever poorly made) cracked into pieces. Took my vehicle to my independent Volvo shop to repair the bushings. The technician, after the repairs were done, notified me that there was a fuel leak coming from the rear fuel tank area. Funny that it was that exact week that I started to notice the gasoline smell, be so ever faint. As of today, September 22, 2008, the smell has become very strong where as even with the windows open while driving, I literally have to stick my nose against the open window to breathe in what should be fresh air.
Noticed a gas smell outside car, coming from rear of car. Car was under warranty, so we returned it to the dealer. The dealer took several attempts to remedy the problem. Finally, the dealer discovered and informed us that the gas tank had a crack and the gasoline was leaking from the crack. After part was replaced, the gas smell went away. Problem was fixed for a few months, and now gas smell has returned. Car is currently at dealer awaiting another repair. While there has been no fire associated with this problem, we are, of course, very afraid that there will be a fire. The gas tank is above the exhaust, so we are concerned that gas might drip or splash on hot components. Dealer informed us that he has seen several other cars with this same problem. I do not have the information on those other cars. However, this appears to be a trend. (dealer in question is crown Volvo of chapel hill, north carolina 919-929-0242).
The consumer stated that this is not the complaint she filed her complaint was about her gas tank door coming off.