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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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167,000 miles · Nov 5, 2014
Electrical SystemEngineSeat Belts

IN OCTOBER 2014 MYSELF MY BOYFRIEND AND MY 7 YEAR OLD WE'RE DRIVING HOME WHEN ALL OF A SUDDEN THE CAR WOULD NOT ACCELERATE WHEN I TRIED TO PUSH THROUGH THE TRAFFIC LIGHT THE VEHICLE THEN SLOWED DOWN IN THE MIDDLE OF THE ROAD THEIR WAS NO WAY OF ME TRYING TO PULL OVER BC THE CAR COMPLETELY STOPPED I THEN PROCEEDED TO GET MY 7 YEA…

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IN OCTOBER 2014 MYSELF MY BOYFRIEND AND MY 7 YEAR OLD WE'RE DRIVING HOME WHEN ALL OF A SUDDEN THE CAR WOULD NOT ACCELERATE WHEN I TRIED TO PUSH THROUGH THE TRAFFIC LIGHT THE VEHICLE THEN SLOWED DOWN IN THE MIDDLE OF THE ROAD THEIR WAS NO WAY OF ME TRYING TO PULL OVER BC THE CAR COMPLETELY STOPPED I THEN PROCEEDED TO GET MY 7 YEAR OLD OUT THE TRUCK AND HER SPELT BELT IN THE BACK WAS STUCK AND WOULD NOT COME OUT WE WERE ALMOST HIT FROM THE BACK DUE TO THE VEHICLE STALLING IN THE MIDDLE OF THE ROAD IN A CURVE WE WERE STRANDED FOR ABOUT THREE HOURS IN THE DARK WHEN WE WERE FINALLY TOWED HOME I WAS TOLD THAT THE TRANSMISSION WAS NO GOOD AND THIS IS THE REASON OUR VEHICLE STALLED AND WAS DISABLED. *TR

NHTSA ODI #10652765

65,000 miles · Sep 29, 2014
Air BagsElectrical SystemSteering

WHILE DRIVING OUR VOLVO XC-90, THE ENTIRE ELECTRICAL SYSTEM SHUTS DOWN (DASHBOARD DISPLAY, LIGHTING, AC, POWER WINDOWS, POWER DOOR LOCKS, EVERYTHING ELECTRICAL ETC.). ADDITIONALLY, FOR A SPLIT SECOND THE ENGINE/TRANSMISSION JERKS AND/OR STALLS BEFORE RESUMING. THE FIRST TIME THIS HAPPENED WAS IN 2010 AND NEVER OCCURRED AGAIN F…

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WHILE DRIVING OUR VOLVO XC-90, THE ENTIRE ELECTRICAL SYSTEM SHUTS DOWN (DASHBOARD DISPLAY, LIGHTING, AC, POWER WINDOWS, POWER DOOR LOCKS, EVERYTHING ELECTRICAL ETC.). ADDITIONALLY, FOR A SPLIT SECOND THE ENGINE/TRANSMISSION JERKS AND/OR STALLS BEFORE RESUMING. THE FIRST TIME THIS HAPPENED WAS IN 2010 AND NEVER OCCURRED AGAIN FOR SEVERAL YEARS. THEN SUDDENLY ON A RECENT TRIP IN AUGUST 2014 THIS HAPPENED REPEATEDLY AND THE ELECTRICAL SYSTEM NEVER RETURNED TO OPERATION DURING THAT TRIP. IN THAT AUGUST 2014 OCCURRENCE WE WERE TRAVELING DOWN NARROW STATE HIGHWAY 1 IN BIG SUR, CALIFORNIA. HAD WE LOST CONTROL OF THE VEHICLE DURING THE JERKING EPISODES WE COULD HAVE GONE OFF THE NARROW ROAD AND DOWN THE STEEP CLIFF SIDE TO OUR DEATHS. THIS PUT OUR FAMILY IN A VERY PERILOUS SITUATION. ADDITIONALLY, SINCE THE ABOVE INCIDENT IN LATE AUGUST 2014 THE VEHICLE HAS EXPERIENCED NUMEROUS OTHER FLASHES/JERKING INCIDENTS WHILE AT HIGHWAY SPEEDS. THIS OCCURRENCE SEEMS TO BE INCREASING. THIS IS A VERY DANGEROUS SITUATION AND NEEDS TO BE ADDRESSED WITH A NATIONAL RE-CALL. *TR

NHTSA ODI #10639901

148,000 miles · Sep 10, 2014
Electrical System

I HAVE EXPERIENCED THE KNOWN ISSUE WITH THE CENTRAL ELECTRONIC MODULE MANY TIMES NOW. I HAVE BEEN DRIVING AT HIGHWAY SPEEDS AND THEN EXPERIENCE THE MOMENTARY JERKING, LOSS OF POWER, LOSS OF INSTRUMENT PANEL, AND MORE. SOMETIMES I START MY VEHICLE AND IT STARTS IN LIMP HOME MODE. VERY FRUSTRATING AND DANGEROUS. THIS SHOULD BE REC…

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I HAVE EXPERIENCED THE KNOWN ISSUE WITH THE CENTRAL ELECTRONIC MODULE MANY TIMES NOW. I HAVE BEEN DRIVING AT HIGHWAY SPEEDS AND THEN EXPERIENCE THE MOMENTARY JERKING, LOSS OF POWER, LOSS OF INSTRUMENT PANEL, AND MORE. SOMETIMES I START MY VEHICLE AND IT STARTS IN LIMP HOME MODE. VERY FRUSTRATING AND DANGEROUS. THIS SHOULD BE RECALLED AND REPAIRED BY VOLVO. *TR

NHTSA ODI #10632199

136,298 miles · Aug 29, 2014
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHENEVER THE VEHICLE WAS DRIVEN OVER A BUMP IN THE ROAD OR IF THE CONTACT INADVERTENTLY HIT THE KEY, THE VEHICLE WOULD STALL. THE LATEST FAILURE OCCURRED WHILE DRIVING 70 MPH. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. UPDATED 10/30/14*LJ UPDATED 04/…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHENEVER THE VEHICLE WAS DRIVEN OVER A BUMP IN THE ROAD OR IF THE CONTACT INADVERTENTLY HIT THE KEY, THE VEHICLE WOULD STALL. THE LATEST FAILURE OCCURRED WHILE DRIVING 70 MPH. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. UPDATED 10/30/14*LJ UPDATED 04/27/2015 *JS

NHTSA ODI #10629297

104,000 miles · Aug 28, 2014
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING 55 MPH, THE VEHICLE STALLED INTERMITTENTLY. THE CONTACT STATED THAT THE INSTRUMENT PANEL AND RADIO WOULD SHUT OFF AND THE WINDSHIELD WIPERS ACTIVATED. ALSO, THE ABS AND ANTI SKID TRACTION CONTROL WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOST…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING 55 MPH, THE VEHICLE STALLED INTERMITTENTLY. THE CONTACT STATED THAT THE INSTRUMENT PANEL AND RADIO WOULD SHUT OFF AND THE WINDSHIELD WIPERS ACTIVATED. ALSO, THE ABS AND ANTI SKID TRACTION CONTROL WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING, BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS 104,000. UPDATED 10/8/14*CN THE CONSUMER STATED THE MANUFACTURER WAS NOTIFIED AND DID NOT OFFER ANY ASSISTANCE DUE TO THE VEHICLES AGE. UPDATED 3/23/15 *JS

NHTSA ODI #10629106

104,500 miles · Aug 18, 2014
Electrical SystemExterior Lighting

2004 VOLVO XC90 2.5T ...DRIVING AT ABOUT 65 MPH WITH NO WARNING ALOUD THUMP NOISE, WINDSHIELD WIPER COMES ON RADIO GOES OFF DASH LIGHTS GO OFF, LAST FOR A SEC. THEN RESUMES TO NORMAL . THIS HAS HAPPENED SEVERAL TIMES NOW, WHILE I HAVE ONLY OWNED THIS VEHICLE FOR A MONTH. TODAY IT HAPPENS AGAIN ONLY WORSE ..AFTER THE INITIAL THU…

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2004 VOLVO XC90 2.5T ...DRIVING AT ABOUT 65 MPH WITH NO WARNING ALOUD THUMP NOISE, WINDSHIELD WIPER COMES ON RADIO GOES OFF DASH LIGHTS GO OFF, LAST FOR A SEC. THEN RESUMES TO NORMAL . THIS HAS HAPPENED SEVERAL TIMES NOW, WHILE I HAVE ONLY OWNED THIS VEHICLE FOR A MONTH. TODAY IT HAPPENS AGAIN ONLY WORSE ..AFTER THE INITIAL THUMP AND JERK IT HAPPENS THREE MORE WITHIN 5 MILES THE LAST TIME I WAS GOING ABOUT 35 MPH, BIG THUMP AND JERK, WIPERS COMES ON , RADIO GOES OFF , ALL DASH LIGHTS OFF ..NO HAZARDS AVAILABLE AND I GET SEVERAL WARNINGS ON DASH BRAKE FAILURE , SRS FAILURE AND ANTI SKID FAILURE. .I TURN CAR OFF THEN BACK ON AND CONTINUE HOME...IT HAPPENS AGAIN 5 MINUTES LATER AT 15 MPH....I AM READING MANY, MANY COMPLAINTS LIKE MINE. THIS ISSUE NEEDS TO BE ADDRESSED ASAP. .I ALMOST WAS REAR ENDED TWICE. VOLVO NEEDS TO TAKE RESPONSIBILITY. *TR

NHTSA ODI #10626180

76,000 miles · Aug 12, 2014
Electrical SystemEngine

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD STALL AND UNKNOWN WARNING INDICATORS WOULD ILLUMINATE. IT TOOK THE CONTACT NUMEROUS ATTEMPTS TO RESTART THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THE WINDSHIELD WIPERS ACTIVATED INDEPENDENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD STALL AND UNKNOWN WARNING INDICATORS WOULD ILLUMINATE. IT TOOK THE CONTACT NUMEROUS ATTEMPTS TO RESTART THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THE WINDSHIELD WIPERS ACTIVATED INDEPENDENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 76,000.

NHTSA ODI #10621815

155,000 miles · Aug 4, 2014
Electrical SystemService BrakesSteeringCrash

3 HOURS INTO A 3-1/2 HOUR WEEKEND ROAD TRIP THERE WAS A CLUNK IN THE ENGINE COMPARTMENT. THINKING I HIT A POTHOLE, I CONTINUED ON CAUTIOUSLY. WHILE CONTINUING ON THESE UNFAMILIAR 2 LANE WINDY ROADS GOING 43MPH (THE SPEED LIMIT WAS 55) ABOUT 2 MILES FROM WHERE THE CLUNK HAPPENED MY ENTIRE DASH CLUSTER STOPPED WORKING. ALL MY DOME…

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3 HOURS INTO A 3-1/2 HOUR WEEKEND ROAD TRIP THERE WAS A CLUNK IN THE ENGINE COMPARTMENT. THINKING I HIT A POTHOLE, I CONTINUED ON CAUTIOUSLY. WHILE CONTINUING ON THESE UNFAMILIAR 2 LANE WINDY ROADS GOING 43MPH (THE SPEED LIMIT WAS 55) ABOUT 2 MILES FROM WHERE THE CLUNK HAPPENED MY ENTIRE DASH CLUSTER STOPPED WORKING. ALL MY DOME LIGHTS AND LEG LIGHTS CAME ON. THE CAR CLUNKED HARDER THIS TIME. I LOST POWER TO THE ENGINE, STEERING WAS LIKE TRYING TO TURN A TANK, AND THE BRAKES WERE VERY SPONGY. STILL TRAVELING ON WINDY ROADS WITH LARGE SEMI TRUCKS BEHIND ME AND CARS PASSING BY IN THE OPPOSITE LANE I VEERED TO THE RIGHT TO AVOID BEING REAR ENDED BY A SEMI. NOT BEING ABLE TO STEER OR STOP AS EFFICIENTLY AS BEFORE I COASTED INTO A RESIDENTS 2-3 MAN ROCK LANDSCAPE TRAVELING AT ABOUT 5MPH. I DENTED MY FRONT LICENSE PLATE AND SCRATCHED THE BUMPER. WITH MY HEART POUNDING, I TURNED THE CAR OFF AND GOT OUT TO SEE THE DAMAGE. I WENT TO THE RESIDENTS HOME AND TOLD THEM MY STORY. THEY WERE THANKFUL MY FIANC AND I WERE OKAY. SINCE I HIT ROCK THERE WAS NO DAMAGE DONE TO THEIR LANDSCAPE. AFTER 20 MINUTES I STARTED THE CAR. IT WAS HESITANT TO START. THE BRAKE FAILURE LIGHT WAS ON FOR A FEW SECONDS THEN THE SRS SERVICE WARNING LIGHT CAME ON AND STAYED ON. FOR THE REMAINDER OF THE WEEKEND TRIP THE CAR WOULD LURCH LIKE THE TRANNY WAS SLIPPING. ESPECIALLY AFTER TAKING OFF FROM A STOP LIGHT. IT STILL CLUNKS ONCE IN AWHILE BUT WE ONLY DRIVE IT AROUND TOWN. IT'S CURRENTLY AT A CERTIFIED VOLVO SPECIALIST BEING SERVICED. THIS MORNING ALL LIGHTS STOPPED WORKING AND I COULDN'T GET IT OUT OF THE GARAGE. THE KEY STUCK IN THE IGNITION. IN CONCLUSION, THIS MISHAP COULD HAVE RESULTED IN A SERIOUS INJURY OR FATALITY. IF EVERY CAR OF THIS MAKE AND MODEL IS DOING THIS, THEY NEED TO BE RECALLED AND REPAIRED! *TR

NHTSA ODI #10618859

130,000 miles · Jul 15, 2014
Electrical System

WHILE GOING UP A HILL ABOUT 45 MILE PER HOUR THE LIGHTS ON MY DASH AS WELL AS THE RADIO TURNED OFF. I PULLED OVER TURNED THE CAR OFF AND BACK ON ALL THE LIGHTS RETURNED HOWEVER MY GAS GAUGE NO LONGER WORKS AS WELL AS UNLOCKING BACK DOORS AND DOOR TO GAS TANK. THERE ARE MANY COMPLAINTS ABOUT THIS PART I DON'T SEE WHY THERE ARE NO…

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WHILE GOING UP A HILL ABOUT 45 MILE PER HOUR THE LIGHTS ON MY DASH AS WELL AS THE RADIO TURNED OFF. I PULLED OVER TURNED THE CAR OFF AND BACK ON ALL THE LIGHTS RETURNED HOWEVER MY GAS GAUGE NO LONGER WORKS AS WELL AS UNLOCKING BACK DOORS AND DOOR TO GAS TANK. THERE ARE MANY COMPLAINTS ABOUT THIS PART I DON'T SEE WHY THERE ARE NO RECALLS THIS IS VERY UNSAFE I COULD'VE EASILY CRASHED DUE TO LOSS OF POWER BREAKS AND THE CAR NOT MAKING IT UP THE HILL. *TR

NHTSA ODI #10610630

160,000 miles · Jul 11, 2014
Electrical SystemEngineSteering

DRIVING VEHICLE AT 45MPH AND KEY SWITCHED OUT OF THE "RUN" POSITION WHILE BEING DRIVEN. VEHICLE'S ENGINE COMPLETELY SHUT OFF, RENDERING POWER BRAKES, POWER STEERING AND AIRBAGS AS NOT OPERATIONAL. *TR

NHTSA ODI #10609912

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.