Other Fuel System Tank Mounting Problems of Volvo S60

Gasoline fill overflows frequently when putting in fuel, regardless of amount of fuel already in the tank.

See all problems of the 2004 Volvo S60 🔎.

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. Although Volvo is aware of the problem, they have not notified owners or done a recall but are requiring those with the defective part to discover it and pay for repairs on their own. I think Volvo should refund my repair costs and notify other owners who have the same fuel tank.