← New search

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.

About this comparison →

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
Clear category filter
45,000 miles · Jun 29, 2006
Electrical System

MY 2004 XC90 AWD BEGAN EXPERIENCING ODD ELECTRICAL PROBLEMS THIS SPRING AT ABOUT 45000 MILES. WHILE DRIVING AT CRUISING SPEED, THE VEHICLE WOULD SUDDENLY AND WITHOUT WARNING EXPERIENCE A HARD JERK FOLLOWED BY ACTIVATION OF THE WINDSHIELD WIPERS AND LOSS OF POWER TO THE RADIO. FIRST TIME, THE DEALER COULD NOT REPLICATE THE PROB…

Read full complaint

MY 2004 XC90 AWD BEGAN EXPERIENCING ODD ELECTRICAL PROBLEMS THIS SPRING AT ABOUT 45000 MILES. WHILE DRIVING AT CRUISING SPEED, THE VEHICLE WOULD SUDDENLY AND WITHOUT WARNING EXPERIENCE A HARD JERK FOLLOWED BY ACTIVATION OF THE WINDSHIELD WIPERS AND LOSS OF POWER TO THE RADIO. FIRST TIME, THE DEALER COULD NOT REPLICATE THE PROBLEM BUT DOWNLOADED ELECTRICAL SOFTWARE UPDATES. SAME THING SECOND TIME AND BACK TO DEALER, AGAIN COULD NOT REPLICATE, AND THEY DOWNLOADED TRANSMISSION UPDATES FOCUSING MORE ON THE JERKING ISSUE. THIRD TIME IT HAPPENED, I CONTINUED TO DRIVE THE CAR TO THE DEALER SO THEY COULD SEE WHAT I WAS EXPERIENCING. ON THE WAY THERE, I HAD COMPLETE LOSS OF ELECTRICAL POWER: NO POWER TO SPEEDOMETER, TO GAS GAUGE, TO WINDOWS, TO AIR CONDITIONING, RADIO, ETC. ALSO HAD LESS THAN FULL POWER TO DRIVE WITH. THE DEALER AGAIN DOWNLOADED ELECTRICAL SOFTWARE UPDATES AND GAVE ME THE VEHICLE BACK. SAME PROBLEM FOR 4TH TIME THIS FRIDAY AND THEY TELL ME THEY HAVE PUT NEW COMPUTER INTO CAR. FORTUNATELY THERE HAVE NOT BEEN ANY DEATHS OR CRASHES, BUT THIS DEFECT CAUSES A SERIOUS SAFETY PROBLEM WITHOUT ANY WARNING. *JB

NHTSA ODI #10161073

28,000 miles · Jun 19, 2006
Electrical SystemFire

VEHICLE FIRE IN THE FRONT PASSENGER SIDE OF THE ENGINE COMPARTMENT - LOOKING FOR ANY PROBLEMS NOTED WITH THIS MAKE / MODEL - ONLY THE COMPUTER SYSTEM AND HEADLIGHT FOR THE VEHICLE IS LOCATED IN THIS AREA. *NM

NHTSA ODI #10160147

24,600 miles · Nov 2, 2005
Electrical System

I PARKED MY VEHICLE IN MY DRIVEWAY ON THE EVENING OF FRIDAY, AUGUST 12, 2005. I LEFT ON VACATION THE FOLLOWING MORNING LEAVING MY VEHICLE IN THE DRIVEWAY. I RETURNED FROM VACATION LATE ON THE EVENING OF AUGUST 21, 2005. THE FOLLOWING MORNING WHEN I WENT OUT TO LEAVE FOR WORK, THE VEHICLE WOULD NOT START. I CALLED AAA IN ORDER…

Read full complaint

I PARKED MY VEHICLE IN MY DRIVEWAY ON THE EVENING OF FRIDAY, AUGUST 12, 2005. I LEFT ON VACATION THE FOLLOWING MORNING LEAVING MY VEHICLE IN THE DRIVEWAY. I RETURNED FROM VACATION LATE ON THE EVENING OF AUGUST 21, 2005. THE FOLLOWING MORNING WHEN I WENT OUT TO LEAVE FOR WORK, THE VEHICLE WOULD NOT START. I CALLED AAA IN ORDER TO HAVE THE CAR JUMPED. IT WOULD NOT JUMP. I THEN CALLED THE VOLVO DEALERSHIP AND THEY TOLD ME TO CALL THE VOLVO HOT LINE FOR A TOW. THE VEHICLE WAS TOWED TO THE GENGRAS VOLVO DEALERSHIP IN EAST HARTFORD, CT ON THE MORNING OF AUGUST 22, 2005 AND IT REMAINS THERE AT THIS TIME. THE DEALERSHIP SERVICE DEPARTMENT REPORTS THAT ALL OF THE COMPUTERS ARE MALFUNCTIONING. THEY REPORT THIS TO BE "AN ACT OF GOD" AS IN THE CAR WAS STRUCK BY LIGHTENING. I WAS ADVISED TO REPORT THIS TO MY INSURANCE COMPANY WHICH I DID. AN APPRAISER WAS DISPATCHED TO LOOK AT THE VEHICLE AND THEN SPECIAL ENGINEERS FROM NORTH EASTERN TECHNICAL SERVICES. INC IN FALL RIVER, MA WENT TO THE VOLVO DEALERSHIP TO VIEW THE VEHICLE. THEY REMOVED TWO COMPUTER MODULES WITH PERMISSION OF THE SERVICE DEPARTMENT AND MICROSCOPICALLY EXAMINED THEM TO DETERMINE IF ANY CONNECTORS, CIRCUIT BOARD OR COMPONENT DAMAGE WAS PRESENT. NEITHER MODULE SHOWED ANY INDICATORS OF DAMAGE. AT THIS POINT THE CLAIM HAS BEEN DENIED BY MY INSURANCE COMPANY SAYING THAT THE PROBLEM IS A WARRANTY PROBLEM. VOLVO DISPUTES THIS SAYING IT IS "AN ACT OF GOD". THE VEHICLE IS LESS THAN TWO YEARS OLD AND HAS LESS THAN 24,000 MILES ON IT. I HAVE NOT BEEN ABLE TO DRIVE THE VEHICLE SINCE AUGUST 12, 2005. IT DOES QUALIFY FOR THE LEMON LAW, BUT MORE IMPORTANTLY, I FOUND THAT THERE HAVE BEEN OTHER REPORTED ELECTRICAL SYSTEM FAILURES OF THIS MODEL. I AM CONCERNED THAT THIS IS INDEED A PROBLEM WITH THIS PARTICULAR MODEL AND THE VOLVO IS TRYING TO COVER IT UP. *JB

NHTSA ODI #10141594

10,400 miles · Jul 20, 2005
Electrical System

WE LEASED OUR VOLVO XC90-T ALMOST EXACTLY 1 YEAR AGO TO DATE FROM SOUTH COUNTY VOLVO. LESS THAN 3 MONTHS LATER, THE CAR WOULDN'T START. THEY SAID THAT MY WIFE MUST HAVE LEFT A LIGHT ON; THE BATTERY WAS RECHARGED AND WE TOOK THE CAR BACK. 2 MONTHS LATER, THE CAR AGAIN WOULD NOT START; AGAIN IT WAS TOWED-BACK TO THE DEALERSHIP. TH…

Read full complaint

WE LEASED OUR VOLVO XC90-T ALMOST EXACTLY 1 YEAR AGO TO DATE FROM SOUTH COUNTY VOLVO. LESS THAN 3 MONTHS LATER, THE CAR WOULDN'T START. THEY SAID THAT MY WIFE MUST HAVE LEFT A LIGHT ON; THE BATTERY WAS RECHARGED AND WE TOOK THE CAR BACK. 2 MONTHS LATER, THE CAR AGAIN WOULD NOT START; AGAIN IT WAS TOWED-BACK TO THE DEALERSHIP. THIS TIME, THEY SAID THE BATTERY WAS BAD. THE THIRD TIME THEY SAID THERE WAS BAD SWITCH WHICH CONTROLS THE LIGHTS AND THAT WAS CHANGED. ON THE FOURTH OCCASION, WHICH INCIDENTALLY OCCURRED EXCATLY ONE YEAR LATER ON JULY 7TH, 2005, THEY (AGAIN) SAID WE MUST HAVE LEFT A LIGHT ON...NO ONE CAN BE THAT DUMB, NOT EVEN ME!. I AM FAST LOSING MY CONFIDENCE IN VOLVO!

NHTSA ODI #10129509

1,000 miles · Nov 17, 2004
Electrical SystemSteeringSuspension

I HAVE HAD NUMEROUS FAILURES WITH MY 1990 VOLVO: I AM ON MY THIRD SET OF TIRES, AND I HAVE 30,000 MILES. I HAVE HAD SEVERAL SHOCK ABSORBERS REPLACED ,A TIE ROD BREAK, AND MANY ELECTRICAL PROBLEMS. *AK

NHTSA ODI #10100120

10,000 miles · Sep 19, 2004
Electrical System

SINCE I HAVE OWNED THIS CAR I HAVE HAD SMALL ELECTRICAL PROBLEMS - MOONROOF WON'T OPEN OR CLOSE, G DOOR OPENER NOT WORKING AFTER 3 DAYS, MUST PRESS UNLOCK BUTTON SEVERAL TIMES TO UNLOCK DOORS. ALSO, THE CAR BOUNCES AT ALL SPEEDS, AND SHIFTS LATE. LABOR DAY, 2004, I WAS DRIVING THE CAR WHEN ALL GAGES WENT OUT - SPEED OD, GAS, O…

Read full complaint

SINCE I HAVE OWNED THIS CAR I HAVE HAD SMALL ELECTRICAL PROBLEMS - MOONROOF WON'T OPEN OR CLOSE, G DOOR OPENER NOT WORKING AFTER 3 DAYS, MUST PRESS UNLOCK BUTTON SEVERAL TIMES TO UNLOCK DOORS. ALSO, THE CAR BOUNCES AT ALL SPEEDS, AND SHIFTS LATE. LABOR DAY, 2004, I WAS DRIVING THE CAR WHEN ALL GAGES WENT OUT - SPEED OD, GAS, OIL PRESS, ENTIRE ABS SYSTEM, ETC. I FOUND IT WAS FUSE 24 AND REPLACED IT. THIS FUSE BLEW 4 MORE TIMES OVER THE NEXT 3 DAYS - ONCE IT BLEW WHEN REPLACING IT. THE DEALERSHIP SAID THIS WAS NOT A SAFETY ISSUE AND SCHEDULED REPAIR FOR 2 WEEKS LATER. (THE ABS SYSTEM STILL REPORTED WARNINGS ON THE MESSAGE DISPLAY). ONCE THE DEALERSHIP FINALLY WORKED ON IT, THEY REPLACED THE CENTRAL ELECTRICAL BOX AND ORDERED A NEW TRANSMISSION WHICH STILL NEEDS TO BE INSTALLED. I STILL HAVE THE ABOVE ELECTRICAL PROBLEMS ALONG WITH THE OTHER PROBLEMS WHICH THE DEALERSHIP CLAIMS ARE ALL RELATED. THERE IS 10,000 MILES ON THIS CAR. PREVIOUSLY, I OWNED A 1999 XC. I CONTINUED TO HAVE ELECTRICAL PROBLEMS WITH THIS CAR UNTIL I STARTED IT AT A DAYCARE TO HAVE THE BATTERY EXPLODE. SOLUTION TO THIS PROBLEM WAS TO UPGRADE ME TO THE 2004 WITH THE ASSURANCE THE PROBLEMS I HAD ON THE 1999 WERE "HIGHLY UNUSUAL AND UNHEARD OF". DUE TO MY PAST EXPERIENCE, AND THE VERY SIMILAR PROBLEMS I AM HAVING WITH THE 2004, I FEEL VERY UNSAFE IN THIS VEHICLE. *AK

NHTSA ODI #10091278

Mileage unknown · Sep 13, 2004
Air BagsElectrical SystemSteering

ON AUGUST, 26, 2004 THERE WAS A MAJOR MALFUNCTION IN OUR VOLVO XC90 (2004). WHILE DRIVING WITH 2 SMALL CHILDREN IN CAR SEATS AND 2 ADULTS ON A MAJOR HIGHWAY; SUDDENDLY, THERE WAS NO ACCELERATION IN THE GAS PEDAL AND THE STEARING WHEEL DID NOT FUNCTION. WE MANAGED TO SLOWLY MOVE TO THE SIDE OF THE ROAD FROM WHAT MOMENTUM WAS…

Read full complaint

ON AUGUST, 26, 2004 THERE WAS A MAJOR MALFUNCTION IN OUR VOLVO XC90 (2004). WHILE DRIVING WITH 2 SMALL CHILDREN IN CAR SEATS AND 2 ADULTS ON A MAJOR HIGHWAY; SUDDENDLY, THERE WAS NO ACCELERATION IN THE GAS PEDAL AND THE STEARING WHEEL DID NOT FUNCTION. WE MANAGED TO SLOWLY MOVE TO THE SIDE OF THE ROAD FROM WHAT MOMENTUM WAS LEFT IN THE CAR, AND AVOID AN ACCIDENT. WE WERE OBVIOUSLY VERY SHAKEN UP, AND FIND THIS CAR COMPLETELY UNSAFE. IT HAS BEEN 3 WEEKS NOW GETTING THE RUN AROUND WITH THE CHERRY HILL, NEW JERSEY VOLVO DEALER. THEY SAID "THERE'S NOTHING WRONG WITH THE CAR". THE CAR IS UNSAFE FOR OUR FAMILY, AND PRESENTS A DANGER FOR OTHERS ON THE ROAD. WE ARE AFRAID IT WILL STOP DEAD AGAIN ON A MAJOR HIGHWAY WITH DEATH OR INJURIES OCCURING TO EITHER OURSELVES OR OTHERS. THE DEALER ASKED US WHAT WE WANTED "WE FINALLY SAID, (AFTER THEY SAID THEY'D GET US A NEW SUV AND DID NOT) THAT WE WANT OUR MONEY BACK ($3,000 DEPOSIT) AND WE DON'T WANT THIS CAR THEY SOLD US. TODAY, THEY MADE US TAKE THIS CAR BACK AND THEY ARE REFUSING OUR REQUEST TO REFUND OUR MONEY. ALSO, THE CAR WAS TOWED ON A FLAT BED TRUCK IN TO THE DEALER ON JULY 13TH, 2004 AS THE CAR DID NOT START.. "RELAYS WERE LOOSE IN THE ICM AND CEM ETC.," [WE HAVE THE SERVICE ORDER] ON THIS DAY, THE MESSAGE ON THE CAR SAID SOMETHING TO THE EFFECT "URGENT MALFUNCTION IN SUV AIR BAGS..." AND WE UNLOADED THE FAMILY AND IT WAS TOWED TO THE VOLVO DEALERSHIP. AND THE CAR'S 2 SIDE MIRRORS WORK ONE DAY AND NOT THE NEXT. TOMORROW I TAKE MATTHEW TO HIS FIRST DAY AT PRE-SCHOOL, AND I'M HALF THINKING WHAT IF SOMETHING HAPPENS TO THE CAR WHEN WE'RE DRIVING. IT'S AMAZING TO ME THAT VOLVO CAN LET ME LEAVE THEIR PARKING LOT WITH THIS CAR THIS EVENING, AND THE AREN'T TAKING SAFETY SERIOUSLY AT ALL. SO, AT 11:00 PM I AM UP LETTING THE NHTSA KNOW WHAT'S GOING ON. WE ARE WILLING TO HELP IN ANYWAY WE CAN. SINCERELY, THE LAWRENCE FAMILY.*AK

NHTSA ODI #10090937

Mileage unknown · Dec 4, 2003
Electrical System

XC90 DOES NOT START - THE PROBLEM PERSISTED FOR OVER 4 WEEKS AND DEALER COULD NOT FIX THE PROBLEM. *NLM

NHTSA ODI #10049195

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.