One problem related to tank assembly has been reported for the 2009 Volvo S60. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2009 Volvo S60 based on all problems reported for the 2009 S60.
2009 Volvo S60 awd - when filling with gasoline at various gas stations, gasoline overflows and spills out of the fuel filler neck when the tank is full. This is with the lock mechanism engaged on the gas pump handle. I have observed this at multiple gas stations and different pumps at those gas stations. I have taken other vehicles to the same stations and pumps and filled their tanks in the same fashion, and the lock mechanism on the pump handle automatically disengages and no gas overflows when the tank is full and reaches capacity. I have already taken this vehicle once previously in September 2009 and they found no issue. I am tired of dealing with it and worried about a fire occurring due to this. The gas spills out and on to the paint on that side of the vehicle and onto the ground.