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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40,000 miles · Oct 2, 2009

Fuel System, Gasoline

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT SMELLED A STRONG ODOR OF FUEL OUTSIDE OF THE PARKED VEHICLE AND INSIDE OF THE VEHICLE WHILE DRIVING. THE FAILURE OCCURRENCE WAS INTERMITTENT AND HAS PROGRESSED. AN AUTHORIZED DEALER STATED THAT THE FAILURE WAS CONTRIBUTED TO A CRACKED FUEL PUMP HOUSING. THE VEHICLE HAS NOT BEEN REPAIRED. THE CONTACT WAS EXTREMELY CONCERNED ABOUT THE SAFETY HAZARD. THE FAILURE AND CURRENT MILEAGE WAS 40,000. UPDATED 10/21/09. *LJ UPDATED 10/20/09*JB

NHTSA ODI #10286103

60,000 miles · Sep 11, 2009

Fuel System, Gasoline

FUEL ODOR AND/OR FUEL LEAKAGE. *TR

NHTSA ODI #10283622

47,000 miles · Aug 28, 2009

Fuel System, Gasoline

LAST COUPLE OF DAYS I NOTICED STRONG GAS SMELLS IN THE GARAGE. DROVE THE CAR A SHORT DISTANCE AND PARKED IT BACK IN THE GARAGE. CHECKED A COUPLE MINUTES LATER AND THE GARAGE REEKED OF GASOLINE. WHEN I CHECKED UNDERNEATH I FOUND GAS STAINING THE UNDERSIDE OF THE GAS TANK AND DRIPS ON THE FLOOR. *TR

NHTSA ODI #10282074

159,000 miles · Aug 18, 2009

Fuel System, Gasoline

VOLVO XC90 2004 FUEL PUMP LEAK AT FUEL TANK. *TR

NHTSA ODI #10280840

Mileage unknown · Aug 3, 2009

Fuel System, Gasoline

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AFTER ALMOST 6 MONTHS OF NOT USING MY VEHICLE AND AFTER TAKING IT TO GET ITS MANDATORY MAINTENANCE, ALL OF A SUDDEN I WAS SMELLING GAS FUMES IN MY GARAGE. NOW I HAVE TO REPLACE THE FUEL PUMP AND PAY MORE THAN $1100. IT IS HEALTH HAZARDOUS AND DANGER SITUATION AND I CAN'T BELIEVE THAT VOLVO HASN'T RECALLED THIS PART AFTER SO MANY COMPLAINTS. NO INJURIES, FIRES OR PROPERTY DAMAGE BECAUSE I TOOK MY VEHICLE IMMEDIATELY TO THE DEALERSHIP BUT IT COULD HAD HAPPEN SINCE MY WATER HEATER AND MY VEHICLE WERE IN THE SAME AREA. *TR

NHTSA ODI #10279162

24,000 miles · Feb 3, 2009

Fuel System, Gasoline

FAULTY FUEL PUMP, BROKER FITTING ON INLET, LEAKS GAS. *TR

NHTSA ODI #10257274

61,529 miles · Jan 2, 2009

Fuel System, Gasoline

FUEL PUMP LEAKING CAUSING INTERNAL GAS FUMES WITH PASSENGER HAZARD AND VISIBLE LEAKING OF GASOLINE ONTO ROAD FROM THE PUMP-GAS TANK ASSEMBLY. THE FUEL PUMP WAS ON A WARRANTY FROM STATE OF CALIFORNIA. HOWEVER WHEN DEALER REPLACED FUEL PUMP KIT THE PUMP-ASSEMBLY CONTINUES TO LEAK. CAR IS A 2004 XC-90 VOLVO WITH 60K MILES. *TR

NHTSA ODI #10253585

49,985 miles · Sep 16, 2008

Fuel System, Gasoline

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IN MARCH OF 2008 I NOTICED A STRONG ODOR OF GASOLINE IN THE GARAGE WERE THE VEHICLE WAS STORED. THIS ODOR HAD ALSO PERMEATED THROUGH OUT THE INTERIOR OF THE VEHICLE. CHECKED VEHICLE FOR FUEL LEAKS AND COULD NOT DETERMINE SOURCE DUE TO QUICK EVAPORATION OF FUEL. ON MARCH 17, 08 LOCAL DEALER FOUND LEAK AT TOP OF FUEL TANK UNDER 2ND ROW SEATS. REPLACED FUEL PUMP AND "FAULTY" LEVEL SENSOR. ON MARCH 27, 08 I RETURNED VEHICLE TO DEALER WITH SAME PROBLEM. THEY TRIED TO PACIFY ME BY SAYING IT WAS RESIDUAL ODOR AND WOULD GO AWAY WITH TIME. AFTER INSPECTION BY DEALER, IT WAS STILL LEAKING. SOLUTION PER DOCUMENTATION WAS TO REPLACE LEVEL SENSOR O-RING ON LEFT SIDE. HOWEVER THE TECH INFORMED ME THE FUEL TANK WITH PUMP AND SENDING UNIT WERE ALL REPLACED. ON SEPTEMBER 16, 08 I AM HAVING THE SAME PROBLEM AGAIN. IT IS BACK TO DEALER, STAY TUNED...... *TR

NHTSA ODI #10242480

56,252 miles · Sep 22, 2007

Fuel System, Gasoline

WHILE THE CAR WAS PARKED IN THE GARAGE THERE WAS AN OVERWHELMING SMELL OF GASOLINE. I TOOK THE CAR TO MY MECHANIC. THEY OBSERVED A FUEL LEAK COMING FROM FUEL PUMP HOUSING. A NEW FUEL PUMP WAS INSTALLED. *TR

NHTSA ODI #10203720

23,000 miles · Dec 3, 2004

Fuel System, GasolineTires

WHILE CONSUMER WAS DRIVING REAR PASSENGER'S TIRE BLEW OUT, RESULTING IN DAMAGING THE FUEL LINE. CONSUMER WAS AT A GAS STATION AND REFUELED THE VEHICLE WHEN IT WAS DISCOVERED THAT FUEL WAS LEAKING FROM THE VEHICLE. *AK

NHTSA ODI #10102072

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.