This is a Technical Journal: Washer system layout for identifying leakage points REF NO : ISSUING DEPARTMENT : CAR MARKET : United States and Canada TJ 25153 Technical Service PARTNER : ISSUE DATE : STATUS DATE : 3 US 7510 Volvo Car USA 2016 - 03 - 17 2016 - 03 - 24 FUNC GROUP : FUNC DESC : 3634 Washer Page 1 of 24 Attachment File Name File Size TJ 25153 S60 MY11 - , V60 , S60 , V60CC.pdf 0.8349 MB TJ 25153 S80 MY07 - , V70 MY08 - , XC70 MY08 - . pdf 0.7857 MB TJ 25153 S90 ( 234 ) MY17 - . pdf 1.4623 MB TJ 25153 V90V90CC ( 235236 ) MY17 - . pdf 1.5192 MB TJ 25153 XC90 ( 256 ) MY16 - . pdf 2.1365 MB TJ 25153_XC60 . pdf 0.8801 MB Vehicle Type Eng Struc Week Type Eng Sales Body Gear Steer Model
full bulletin at NHTSA ↗2005 Volvo S60 fuel system problems
moderate 6 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Complaints
6
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 6 fuel system complaints filed for the 2005 Volvo S60, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA fuel system complaint has been filed on this vehicle in over 14 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
VOLVO: LEAKAGE DETECTION DIAGNOSTICS IMPROVEMENTS TO REMEDY DTC'S. ALL MODELS FROM MODEL YEARS 2003-2008. DIAGNOSTIC MONITOR FOR THE EVAPORATIVE EMISSION SYSTEM SMALL LEAK, HAS USED A SOFTWARE FUNCTION THAT CALCULATES LEAKAGE BASED ON A PRESSURE INFERRED FROM THE CURRENT CONSUMED BY AN ELECTRIC PUMP THAT PUMPS AIR INTO THE FUEL TANK SYSTEM.
full bulletin at NHTSA ↗FUEL PUMP CONTROL MODULE REPLACEMENT.
full bulletin at NHTSA ↗INSTALLING EXTRA FUEL PUMP FEED CABLE.
full bulletin at NHTSA ↗LEAKAGE DIAGNOSTIC FUNCTION IMPROVEMENTS TO REMEDY DTC'S. UPDATED 1/22/08. UPDATED 4/7/08.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 3 most recent
Intermittent sudden loss of power at freeway speeds and in town .. Very dangerous !!! Fuel pressure switch part no. 8699449 has failed. Volvo model s60 in years 2003, 2004 have been recalled for same problem. Volvo model s40 & v70 in year 2005 & 2006 have been recalled for same problem. The pressure switch with part number 8699449 is the real problem across all Volvo models and recalls…
Without warning or other problems, the car's engine suddenly lost power at about 55 MPH on the highway, message of "reduced engine performance" came on. Although the car remained turned on, pressing on the gas pedal had little to no effect on either the movement of the car or the RPM's. Once the car was stopped but was still turned on, it maintained a strong "pulsing" action and sound from the…
I have seen the recall of Volvo s60 models 2001-2005 in us in regards to the fuel pump cracks in flange and thus leak of fuel which may result in a fire. I am currently (since 7 days of the date of writing this complaint) having the same problem with my car (Volvo s60 model 2005) in uae/ abu dhabi. The dealer along with the service managers and workshop refused to carry the repair free of charge…
Had fuel system trouble with your 2005 Volvo S60?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Volvo S60?
It's a documented issue but not catastrophic. 6 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 6 complaints filed, fuel system issues most often appear around 57,694 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Volvo/S60.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.