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2004 Volvo XC90

Owner reports · Recalls · Investigations

More warning signs than most XC90 years

Owner complaints for the 2004 Volvo XC90 are substantially higher than the model-year median of 34.

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When problems were reported

Mileage at the reported incident

410 reports with mileage · 52 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 158 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 145 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports3 fire reports7 injury reports

Electrical System complaints

158 reports
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87,000 miles · Jun 22, 2011
Electrical System

2004 VOLVO XC90 JERKED, THEN ALL ELECTRIC COMPONENTS WENT OUT SUDDENLY INCLUDING HEADLIGHTS AS WE DROVE ALONG TN HWY 840 CAUSING US TO ALMOST WRECK AS IT WAS NIGHTTIME AND PITCH BLACK ON THIS HIGHWAY. PULLED OVER AND RESTARTED SUV. NORMAL ACTIVITY FOR 30 MINUTES, THEN PROBLEM RECURRED. TOOK SUV TO VOLVO DEALERSHIP AND THEY RE…

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2004 VOLVO XC90 JERKED, THEN ALL ELECTRIC COMPONENTS WENT OUT SUDDENLY INCLUDING HEADLIGHTS AS WE DROVE ALONG TN HWY 840 CAUSING US TO ALMOST WRECK AS IT WAS NIGHTTIME AND PITCH BLACK ON THIS HIGHWAY. PULLED OVER AND RESTARTED SUV. NORMAL ACTIVITY FOR 30 MINUTES, THEN PROBLEM RECURRED. TOOK SUV TO VOLVO DEALERSHIP AND THEY REPLACED FAULTY CEM. *TR

NHTSA ODI #10408454

80,000 miles · Jun 19, 2011
Electrical System

I WAS DRIVING MY 2004 XC90 ON THE HIGHWAY WHEN SUDDENLY ALL THE LIGHTS IN THE DASHBOARD WENT OUT. THE CAR SLOWED DOWN. EVERYTHING ELECTRICAL IN THE CAR STOPPED WORKING. I COULD STILL START THE CAR HOWEVER. BUT ACCELERATION WASN'T THE SAME, THE CAR CRAWLED. TOOK THE CAR TO THE VOLVO DEALERSHIP WHO SAY THIS IS A CEM PROBLEM. A COM…

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I WAS DRIVING MY 2004 XC90 ON THE HIGHWAY WHEN SUDDENLY ALL THE LIGHTS IN THE DASHBOARD WENT OUT. THE CAR SLOWED DOWN. EVERYTHING ELECTRICAL IN THE CAR STOPPED WORKING. I COULD STILL START THE CAR HOWEVER. BUT ACCELERATION WASN'T THE SAME, THE CAR CRAWLED. TOOK THE CAR TO THE VOLVO DEALERSHIP WHO SAY THIS IS A CEM PROBLEM. A COMPUTER DEFECT THE CAR IS BARELY 7 YEARS OLD AND THIS IS APPARENTLY A PROBLEM WITH MANY OTHER XC90 OWNERS AND A REAL SAFETY ISSUE. AND TO REPLACE THIS CEMCHIP IS 1400 DOLLARS. LEASE LOOK INTO THIS MATTER. *TR

NHTSA ODI #10407450

80,000 miles · Jun 7, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHEN DRIVING THE VEHICLE FOR MORE THAN ONE HOUR, THE VEHICLE WOULD EXHIBIT ELECTRICAL FAILURES. THE INSTRUMENT PANEL WOULD FAIL AND WHEN THE VEHICLE WAS TURNED OFF AND THEN RESTARTED, THERE WERE SEVERAL WARNING LIGHTS ILLUMINATED SPORADICALLY. THE CONTACT TOOK THE V…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHEN DRIVING THE VEHICLE FOR MORE THAN ONE HOUR, THE VEHICLE WOULD EXHIBIT ELECTRICAL FAILURES. THE INSTRUMENT PANEL WOULD FAIL AND WHEN THE VEHICLE WAS TURNED OFF AND THEN RESTARTED, THERE WERE SEVERAL WARNING LIGHTS ILLUMINATED SPORADICALLY. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE VEHICLE WOULD NEED A SOFTWARE UPGRADE. THE CONTACT STATED THAT THE UPGRADE TEMPORARILY CORRECTED THE PROBLEM, BUT THE FAILURE RECURRED WHEN THE WEATHER BECAME WARMER. THE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 91,000.

NHTSA ODI #10405394

124,500 miles · May 31, 2011
Electrical System

2004 XC-90 AWD: FOR OVER TWO YEARS THE VEHICLE HAS BEEN EXPERIENCING THE SAME ISSUE WHICH APPEARS TO BE AN ELECTRICAL PROBLEM. THE VEHICLE WILL SUDDENLY SEEM TO STALL OR "HICCUP" WHILE DRIVING. THIS OCCURS AT ANY SPEED BUT IT IS MOST PREVALENT AT HIGHWAY SPEEDS. IT NORMALLY HAPPENS AT SPEEDS OF 65MPH OR HIGHER. THE WINDSHIE…

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2004 XC-90 AWD: FOR OVER TWO YEARS THE VEHICLE HAS BEEN EXPERIENCING THE SAME ISSUE WHICH APPEARS TO BE AN ELECTRICAL PROBLEM. THE VEHICLE WILL SUDDENLY SEEM TO STALL OR "HICCUP" WHILE DRIVING. THIS OCCURS AT ANY SPEED BUT IT IS MOST PREVALENT AT HIGHWAY SPEEDS. IT NORMALLY HAPPENS AT SPEEDS OF 65MPH OR HIGHER. THE WINDSHIELD WIPERS WILL ENGAGE FOR ONE SWEEP (THEY WILL BE SELECTED ?OFF?), THE RADIO (IF ON) WILL TURN OFF AND ON AGAIN, THE GAUGES ON THE PANEL WILL GO DEAD AND THEN COME TO LIFE. THE MOST UNSAFE THING IS A LOUD ?THUMP? THAT OCCURS IN THE FRONT OF THE VEHICLE. IT FEELS LIKE SOMEONE HAS SUDDENLY SLAMMED ON THE BRAKES AND THEN RELEASED THEM. THIS ALL HAPPENS IN A MATTER OF SECONDS. THE ENGINE DOES NOT STOP DURING THIS SEQUENCE AND THE BRAKES APPEAR TO KEEP WORKING. THIS HAS OCCURRED WITH AND WITHOUT THE CRUISE CONTROL ENGAGED. THERE ARE NO WARNINGS, LIGHTS, OR CAUTION MESSAGES ASSOCIATED WITH THIS DURING OR AFTER IT OCCURS. NONE OF THE DEALERSHIPS WE'VE TAKEN IT TO HAVE DISCOVERED THE CAUSE. I RECENTLY DISCOVERED A NHTSA INVESTIGATION THAT WAS COMPLETED IN NOVEMBER 11, 2010 ON 20 CASES INVOLVING SIMILAR ISSUES WITH 2004 XC-90S. THE INVESTIGATION NUMBER IS PE10-025. IT APPEARS THE PROBLEM MAY BE ELECTRICAL BUT NEITHER I NOR THE DEALERSHIPS CAN NARROW IT DOWN. THE VEHICLE HAS APPROXIMATELY 125K MILES ON IT. I HAVE BEEN THE ONLY OWNER OF THE VEHICLE AND ALL REQUIRED MAINTENANCE HAS BEEN KEPT UP TO DATE WITH VOLVO DEALERSHIPS IN WICHITA, KS, STOCKTON, CA AND NOW TACOMA, WA. MOST RECENTLY THIS OCCURRED THREE TIMES DURING A DAY TRIP WHICH COVERED APPROXIMATELY 288 MILES. *TR

NHTSA ODI #10403884

Mileage unknown · May 31, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHEN DRIVING VARIOUS SPEEDS, HE COULD HEAR A CLICKING NOISE COMING FROM UNDER THE DASHBOARD AND VARIOUS LIGHTS ON THE INSTRUMENT PANEL WOULD ILLUMINATE RAPIDLY. THE FAILURE RECURRED INTERMITTENTLY. THE CONTACT ALSO STATED THAT AFTER THE MOST RECENT FAILURE, HE WAS U…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHEN DRIVING VARIOUS SPEEDS, HE COULD HEAR A CLICKING NOISE COMING FROM UNDER THE DASHBOARD AND VARIOUS LIGHTS ON THE INSTRUMENT PANEL WOULD ILLUMINATE RAPIDLY. THE FAILURE RECURRED INTERMITTENTLY. THE CONTACT ALSO STATED THAT AFTER THE MOST RECENT FAILURE, HE WAS UNABLE TO START THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO HAVE THE FAILURE DIAGNOSED OR REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE UNAVAILABLE. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10403837

123,000 miles · May 29, 2011
Air BagsElectrical SystemExterior Lighting

WAS DRIVING AT HIGHWAY SPEED WHEN ALL ELECTRICAL SYSTEMS SHUT DOWN. DASH PANEL INDICATED BRAKE FAILURE, STOP CAREFULLY. NO LIGHTS, TURN SIGNALS, SPEEDOMETER, TACHOMETER, AIRBAGS, HAZARD LIGHTS, PWR WINDOWS, PWR BRAKES, RADIO - NO POWER TO ANYTHING. CLEAR, DRY WEATHER CONDITIONS. THIS HAD BEEN HAPPENING FOR SHORT CYCLES FOR APPRO…

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WAS DRIVING AT HIGHWAY SPEED WHEN ALL ELECTRICAL SYSTEMS SHUT DOWN. DASH PANEL INDICATED BRAKE FAILURE, STOP CAREFULLY. NO LIGHTS, TURN SIGNALS, SPEEDOMETER, TACHOMETER, AIRBAGS, HAZARD LIGHTS, PWR WINDOWS, PWR BRAKES, RADIO - NO POWER TO ANYTHING. CLEAR, DRY WEATHER CONDITIONS. THIS HAD BEEN HAPPENING FOR SHORT CYCLES FOR APPROX. 2 MONTHS. WINDSHIELD WIPERS WOULD TURN ON FOR ONE CYCLE AND ALL POWER WOULD SHUT DOWN TO DASH, RADIO, LIGHTS ETC. BUT WOULD LAST FOR ONLY A SECOND OR TWO. THIS MIGHT HAPPEN 2-3 TIMES ON APPROX. 20 MILE DRIVE HOME ON HIGHWAY. THIS ONLY HAPPENS AT HIGHWAY SPEED. BUT THE INCIDENT ON THURSDAY 05.26.11 NO POWER LASTED FOR 10 MILES UNTIL I GOT THE VEHICLE HOME. HAD THE CAR SIT FOR AN HOUR AND THEN STARTED AGAIN AND THE DASH INDICATED SRS SYSTEM FAILURE BUT ALL POWER WAS RESTORED TO CAR.

NHTSA ODI #10404758

74,000 miles · May 23, 2011
Electrical System

THIS IS IN REGARDS TO MY VOLVO 2004 XC90. WHILE DRIVING MY VOLVO STARTS JERKING AND THEN ALL OF THE ELECTRICAL SYSTEMS GO OUT - ALL THE INTERIOR DASH LIGHT GO OFF, SIGNAL LIGHTS, AND HAZARDS WILL NOT WORK. I GET A MESSAGE ABOUT BRAKE FAILURE AND THEN SRS AIRBAG SERVICE. ONCE YOU STOP THE CAR AND RESTART IT FUNCTIONS NORMALLY WIT…

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THIS IS IN REGARDS TO MY VOLVO 2004 XC90. WHILE DRIVING MY VOLVO STARTS JERKING AND THEN ALL OF THE ELECTRICAL SYSTEMS GO OUT - ALL THE INTERIOR DASH LIGHT GO OFF, SIGNAL LIGHTS, AND HAZARDS WILL NOT WORK. I GET A MESSAGE ABOUT BRAKE FAILURE AND THEN SRS AIRBAG SERVICE. ONCE YOU STOP THE CAR AND RESTART IT FUNCTIONS NORMALLY WITH JUST THE SRS MESSAGE REMAINING. *TR

NHTSA ODI #10402491

110,000 miles · May 9, 2011
Electrical SystemExterior Lighting

ENGINE WARNING LIGHT ALERTED A "BULB FAILURE". REPLACEMENT OF THE HEADLAMP CARTRIDGE DID NOT FIX THE PROBLEM. SINCE THE INCIDENT HAPPENED, I NOTICED SEVERAL OTHER XC90 SUV'S WITH SAME DAYLIGHT LAMP OUT ON THE DRIVER SIDE.

NHTSA ODI #10400367

113,000 miles · Apr 21, 2011
Electrical System

I OWN A 2004 VOLVO XC-90. I HAVE OWNED IT SINCE 12/2007. APPROXIMATELY 7 MONTHS AGO I STARTED HAVING INTERMITTENT ELECTRICAL PROBLEMS (NAVIGATION FAILURE, ENGINE SERVICE ALERTS, SECURITY ALARM SYSTEM FAILURE). MESSAGES WOULD APPEAR AND THEN STOP. RECENTLY WHILE DRIVING IN THE MOUNTAINS A MESSAGE APPEARED ABOUT A POSITION …

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I OWN A 2004 VOLVO XC-90. I HAVE OWNED IT SINCE 12/2007. APPROXIMATELY 7 MONTHS AGO I STARTED HAVING INTERMITTENT ELECTRICAL PROBLEMS (NAVIGATION FAILURE, ENGINE SERVICE ALERTS, SECURITY ALARM SYSTEM FAILURE). MESSAGES WOULD APPEAR AND THEN STOP. RECENTLY WHILE DRIVING IN THE MOUNTAINS A MESSAGE APPEARED ABOUT A POSITION LIGHT FAILURE, THEN PROGRESSED TO MULTIPLE LIGHT FAILURES. THIS OCCURRED AT NIGHT ON THE BLUE RIDGE PARKWAY WHICH IS POORLY LIT IN MANY AREAS AND HAS WINDING ROADS WITH STEEP DROP OFFS. WE HAD TO DRIVE WITH MY PASSENGER AIMING A FLASHLIGHT TO SEE THE ROAD UNTIL WE COULD TURN OFF ON AN EXIT. THERE IS NO WHERE ON MOST OF THE PARKWAY TO PULL OFF AND WE WERE AT GREAT RISK WITHOUT HEADLIGHTS. WE CHECKED FUSES, AND THEN STARTED AGAIN AND HEADLIGHTS WORKED, SO DROVE ON. LATER ON THE INTERSTATE THEY FAILED AGAIN AND WE HAD TO PULL OFF AND PARK AND GET ANOTHER RIDE HOME. VOLVO CONFIRMED THAT THE CEM FAILURE IS A VERY COMMON OCCURRENCE WITH XC90S. THEY USED TO KEEP SOME OF THESE ON HAND DUE TO COMMON NEED TO REPLACE. AS WITH OTHER OWNERS, I NOW HAVE A $1200+ REPAIR TO REPLACE THIS. THIS SHOULD BE A RECALL ITEM - HIGH RATE OF OCCURRENCE AND SAFETY ISSUE. WHY WAIT UNTIL SOMEONE IS KILLED? IT IS ONLY A MATTER OF TIME TILL HAPPENS WITH CEM FAILURES.. *TR

NHTSA ODI #10397056

62,000 miles · Mar 21, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE CONTACT NOTICED A LOUD THUMPING NOISE COMING FROM THE FRONT END OF THE VEHICLE FOLWED BY THE ILLUMINATION OF ALL WARNING LIGHTS INCLUDING THE CHECK ENGINE, ABS AND SRS WARNING LIGHTS. THE ENGINE CONTINUED TO RUN; HOWEVER, ALL THE ELECTRICAL POWER FAILED. …

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE CONTACT NOTICED A LOUD THUMPING NOISE COMING FROM THE FRONT END OF THE VEHICLE FOLWED BY THE ILLUMINATION OF ALL WARNING LIGHTS INCLUDING THE CHECK ENGINE, ABS AND SRS WARNING LIGHTS. THE ENGINE CONTINUED TO RUN; HOWEVER, ALL THE ELECTRICAL POWER FAILED. THE DEALER ADVISED THE CONTACT TO BRING THE VEHICLE IN FOR DIAGNOSTIC TESTING. THE CONTACT DID NOT INFORM THE MANUFACTURER SINCE HE WAS AWAITING A SERVICE APPOINTMENT WITH THE DEALER. THE CURRENT AND FAILURE MILEAGE WAS 62,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10392400

Official recalls

6

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence & remedy

Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.

Consequence & remedy

Consequence: IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

06V155000 · Steering:linkages:tie Rod Assembly

May 5, 2006

ON CERTAIN PASSENGER VEHICLES,THE OUTER TIE ROD BALL JOINT CAN DEFORM AT HIGH LOADS CAUSING A LOSS OF THE CLAMPING FORCE AND THE NUT MAY LOOSEN, WHICH MAY EVENTUALLY LEAD TO A FATIGUE FRACTURE OF THE OUTER TIE ROD BALL JOINT.

Consequence & remedy

Consequence: THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE OUTER BALL JOINT TIE RODS WITH IMPROVED OUTER BALL JOINT TIE RODS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 23, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

06V144000 · Visibility:windshield Wiper/washer

Apr 28, 2006

ON CERTAIN VEHICLES, IF THE WIPER ARM IS ACTIVATED IN EXTREME WINTER WEATHER CONDITIONS AND WITHOUT LIFTING THE WIPER ARMS AND CLEANING THE WINDSHIELD PRIOR TO MOVING, THE WIPER ARM MIGHT SLIP ON ITS DRIVESHAFT, RESULTING IN AN INABILITY TO MOVE THE WIPERS FROM THE PARK POSITION.

Consequence & remedy

Consequence: INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.

Remedy: DEALERS WILL REPLACE THE WIPER ARMS AND RETAINING NUTS. THE RECALL BEGAN ON SEPTEMBER 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

03V434000 · Wheels

Nov 4, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.

Consequence & remedy

Consequence: THIS CAN ADVERSELY AFFECT A NUMBER OF VEHICLE FUNCTIONS, INCLUDING BRAKE, ENGINE, TRANSMISSION, AND TORQUE DISTRIBUTION CONTROL WHICH RELY ON THIS SIGNAL FOR PROPER OPERATION.

Remedy: DEALERS WILL REPLACE THE FRONT WHEEL SENSORS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

03V391000 · Seat Belts:rear/other

Oct 10, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.

Remedy: DEALERS WILL INSPECT AND REPAIR THE SECOND AND/OR THIRD ROW SEAT BELT ATTACHMENTS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

PE10025 · Central Electronic Module Failure

Opened Jul 20, 2010 · Closed Nov 22, 2010

Status: closed (inferred from source dates) · Electrical System

Volvo acknowledged a problem affecting some subject vehicles involving water seepage into the plenum box area in the engine compartment.When this occurs water may enter into the interior / passenger compartment and track along the wiring harness for the Central Electronic Module (CEM), the device that controls many of the vehicle's electrical functions including wiper operation, lighting, and transmission operation.If the water reaches the CEM connector electrical faults may result.In response to such faults the CEM, a microprocessor controlled device, will attempt to reset by temporarily shutting down (for 100 milliseconds, or 0.1 seconds) and restarting; this effects various CEM functions including the instrument panel (IP) display, gauges, wipers and also the transmission gear (if it is in the overdrive range).During the reset owners may experience temporarily loss of the IP displays and an abnormal 'jerking' in the transmission/drivetrain.If the problem persist for 6 consecutive restart attempts, the CEM will enter a 'Limp Home' mode that disables non-essential electrical functions yet maintain safety critical functions such as low-beam headlights, low-speed wiper operation, brake lights, and non-overdrive transmission operation.Warning and error messages will also be illuminated in the IP display.Consumers reported experiencing conditions consistent with CEM resetting and the limp mode operation in their reports to both ODI and Volvo.No reports or allegations of crash or injury associated with possible CEM failures have been reported by Volvo or otherwise identified by ODI.Volvo revised the design of the wiring grommet (sealing device) and the plenum cover starting in May 2005 and October 2005 production dates respectively, the occurrence of the condition effectively ended after these changes.A technical service bulletin (TNN 37-35) has been published to diagnose and repair earlier production vehicles using the improved wiring grommet and/or new plenum cover.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.

PE09039 · Fuel Pump Leak

Opened Aug 31, 2009 · Closed Dec 22, 2009

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

Additional source detail variants (4)

Fuel System, Gasoline:delivery:fuel Pump

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

Fuel System, Gasoline:delivery

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

Fuel System, Gasoline

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

PE05064 · Windshield Wiper Arm Performance

Opened Dec 2, 2005 · Closed May 10, 2006

Status: closed (inferred from source dates) · Visibility:windshield Wiper/washer:linkages

THE MANUFACTURER NOTIFIED NHTSA BY LETTER DATED APRIL 21, 2006, THAT A SAFETY RECALL HAS BEEN INITIATED FOR CORRECTION OF THIS PROBLEM ON CERTAIN MODEL YEAR 2003 - 2006 VOLVO XC90 VEHICLES. THE RECALL AFFECTS APPROXIMATELY 122,400 SUBJECT VEHICLES PRODUCED BETWEEN AUGUST 2002 AND OCTOBER 2005.NHTSA HAS ASSIGNED NO. 06V-144 TO THIS RECALL ACTION.THE CORRECTIVE ACTION WILL CONSIST OF REPLACING THE EXISTING WINDSHIELD WIPER ARMS WITH A NEW REINFORCED DESIGN.BASED ON THIS ACTION, THE SUBJECT PE HAS BEEN CLOSED.