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

Fuel System, Gasoline complaints

40 reports

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86,603 miles · Nov 24, 2009

Fuel System, Gasoline

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MY 2004 VOLVO XC-90 BEGAN TO EMIT A STRONG FUEL ODOR WHEN PARKED IN MY GARAGE. I DID NOT NOTICE ANY FUEL LEAKAGE (I.E. STAINS ON THE GROUND UNDER THE CAR). I BEGAN PARKING MY CAR OUTSIDE AS THE GAS WATER HEATER IS LOCATED IN THE GARAGE. THE FUEL ODOR IS NOTICEABLE BOTH IN THE CAR WHEN DRIVING AND WHEN PARKED. I TOOK THE VEHICLE TO THE DEALER TO DIAGNOSE AND REPAIR. THE DEALER REPLACED THE FUEL PUMP AND BECAUSE I MENTIONED SIMILAR COMPLAINTS LOGGED FROM THIS WEBSITE, I WAS ONLY CHARGED FOR THE LABOR ($784). AFTER THE VEHICLE WAS RETURNED TO ME, I WASHED THE UNDERCARRIAGE WELL AND PARKED OUTSIDE FOR SEVERAL DAYS TO "AIR" IT OUT. I BEGAN PARKING IN THE GARAGE AGAIN AND THE FUEL ODOR WAS STILL PRESENT (THE GARAGE DOES NOT HAVE A FUEL ODOR WHEN THE VEHICLE IS NOT PARKED IN IT.). I BOUGHT AND REPLACED THE GAS CAP AS I NOTICED THAT THE RUBBER GASKET WAS CRACKED. THAT DID NOT HELP. I HAVE SINCE TAKEN IT BACK TO THE DEALER FOR MORE DIAGNOSIS AND REPAIR. THIS IS A MAJOR SAFETY CONCERN! I FIND IT HARD TO BELIEVE THAT THERE HAS NOT BEEN A VOLUNTARY RECALL. I AM CURIOUS AS TO THE RESULT OF NHTSA'S PRELIMINARY EVALUATION (PE09-039) OF SIMILAR COMPLAINTS, OF WHICH THE NUMBER OF COMPLAINTS SEEMS TO BE INCREASING EVERYTIME I LOOK AT THIS WEBSITE. PLEASE HELP! *TR

NHTSA ODI #10293452

50,000 miles · Nov 16, 2009

Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO XC90. SHE SMELLED A STRONG ODOR OF GASOLINE COMING FROM HER VEHICLE WHILE PARKED. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE TECHNICIAN STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED AT AN EXPENSE OF $1200.00. THE FAILURE MILEAGE 50,000. THE VEHICLE IDENTIFICATION NUMBER WAS UNAV…

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NHTSA ODI #10292300

Mileage unknown · Nov 14, 2009

Fuel System, Gasoline

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I HAVE A 2004 XC90 THAT HAS A FUEL PUMP DAMAGE. THERE IS SOME SORT OF A LEAK WHERE THE GAS ODOR COMES IN THE CABIN. I BROUGHT IT OUT TO THE DEALER AND IT WOULD COST ME CLOSE TO A $1000 TO FIX IT. I'VE HEARD OF PEOPLE WITH SIMILAR PROBLEM AND I BELIEVE IT TO BE BIGGER PROBLEM THAN WHAT VOLVO SAID TO ME. THEY SAID IT WAS WEAR AND TEAR BUT I HAVE FRIENDS THAT DRIVE DIFFERENT CARS AND I'VE NEVER HEARD OF FUEL PUMP PROBLEM. CAN YOU LET ME KNOW IF THIS IS AN ISOLATED PROBLEM OR A COMPANY-WIDE ISSUE? THANKS. *TR

NHTSA ODI #10292161

68,000 miles · Nov 8, 2009

Fuel System, Gasoline

PERSISTENT STRONG GAS SMELL IN/OUT OF CAR. UPON INVESTIGATION, GAS LEAK ON/AROUND FUEL PUMP WITH RESIDUE VISIBLE ON BOTTOM OF GAS TANK. *TR

NHTSA ODI #10291399

75,000 miles · Nov 4, 2009

Fuel System, Gasoline

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT SMELLED FUEL IN THE VEHICLE AND OBSERVED THAT THERE WAS A LEAK IN THE FUEL TANK. THE MECHANIC CONFIRMED THAT THE FUEL PUMP GASKET CAUSED THE FAILURE. THE MANUFACTURER ADVISED HER TO CONTACT THE DEALER AND OFFERED TO PAY FOR THE REPAIR MINUS THE SERVICE CHARGE. THE VEHICLE HAS NO…

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NHTSA ODI #10290969

69,500 miles · Nov 2, 2009

Fuel System, Gasoline

MY 2004 VOLVO XC90 HAD TO HAVE THE FUEL PUMP REPLACED BECAUSE IT WAS LEAKING FUEL AND THERE WAS A STRONG ODOR OF FUEL IN THE CAR AND WHEN IT WAS STOPPED. *TR

NHTSA ODI #10290719

53,000 miles · Oct 29, 2009

Fuel System, GasolineInjury

2004 VOLVO XC 90 FUEL PUMP LEAK. STRONG ODOR EMITS FROM VEHICLE. SPOKE WITH VOLVO NA HQ, HAS NO DOCUMENTS ON THIS. HOWEVER, OTHER GOV AND VEHICLE REPORTING AGENCIES HAVE DOCUMENTS SUPPORTING EVIDENCE OF COMPLAINTS ON SAME VEHICLE. AT THIS TIME NO RECALL ISSUED. IF RECALL IS ISSUED, CONSUMER IS "ENTITLED TO REIMBURSEMENT". LI…

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NHTSA ODI #10290276

Mileage unknown · Oct 15, 2009

Fuel System, Gasoline

2004 VOLVO XC90-STRONG ODOR OF GASOLINE. THE SMELL BECOMES MORE PUNGENT AFTER DRIVING AND FILLING UP. *TR

NHTSA ODI #10287462

75,000 miles · Oct 13, 2009

Fuel System, Gasoline

MY '04 VOLVO XC90 @75K MILES SUDDENLY DEVELOPED A FUEL LEAK IN THE REGION OF THE FUEL PUMP. FUEL IS LEAKING AT A STEADY RATE (THE ENTIRE TANK IN A FEW DAYS). *TR

NHTSA ODI #10287165

116,000 miles · Oct 8, 2009

Fuel System, Gasoline

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MY 2004 VOLVO XC90 HAS A FUEL LEAK COMING FROM SOMEWHERE IN THE REGION OF THE FUEL PUMP, HOSE OR GAS TANK. I AM TOLD BY THE VOLVO MECHANIC THAT THEY ARE SEEING ALOT OF FUEL PUMP AND FITTING FAILURES. I AM ALSO SEEING ONLINE REPORTS OF OTHER OWNERS WITH SAME PROBLEM. AND I SEE THAT THE FUEL PUMP AND FITTINGS ARE THE SAME OR SIMILAR THAT HAVE BEEN RECALLED ON OTHER VOLVO MODELS AND OTHER MODEL YEARS. I SEE YOU HAVE AN ACTIVE INVESTIGATION INTO THIS PROBLEM. ANY ADVICE? WILL THERE BE A RECALL SOON? $2000- 3000 FOR REPAIR OF A DEFECTIVE ALREADY RECALLED ITEM ON OTHER VEHICLES SEEMS EXCESSIVE? *TR

NHTSA ODI #10286721

Official recalls

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

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

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

Fuel System, Gasoline:delivery

Fuel System, Gasoline

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.