My 2004 Volvo V70 wagon spewed and spit gas when being filled with gasoline. When the automatic shut off from the gas pump engaged, gas from the tank and the filler line gushed and poured out of the tank. This happened on several occasions including the very first time I filled the vehicle with gas. It also occurred when I attempted to fill the gas tank slowly so that pressure would not eject gasoline from the tank. The car was brought to the dealer where it was purchased (smith co. Motors - charleston, wv) for the problem to be fixed on March 31, 2004. After inspecting valves in the gas tank and fuel filler tube, the dealer contacted me to tell me no problem had been found. I asked the dealer service manager if the tank had been filled with gas to make sure gasoline did not continue to gush from the tank. The dealer then filled the tank and called to me to confirm that the problem had not been fixed. The car was then at the dealer and out of service until April 8, 2004, when a Volvo representative discovered that the car had a manufacturing defect. I was told the defect was that a valve had not been installed on the car at the factory. On April 12, 2004 I returned home from work and pulled into my driveway. I left the car running in my driveway. After 1 to 2 minutes inside, I notice a strong smell of gasoline. The car had stopped running and was freely spilling gallons of gasoline into my driveway. The dealer discovered a new gas tank had not been properly installed by the service technician. I am interested in NHTSA investigating if the repeated failures of my fuel system are related. I am further interested in NHTSA determining if other 2004 Volvo with similar fuel system components could have also left the factory without a completely assembled fuel system. I encountered a very serious safety problem that could have resulted in a catastrophic accident.

- Huntington, WV, USA