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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

Exterior Lighting complaints

32 reports
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120,000 miles · Nov 6, 2013
Exterior Lighting

BOTH HEADLIGHTS WENT OUT AT THE SAME TIME. I WAS ON INTERSTATE 77 BOTH LIGHTS WENT OUT DIDN'T KNOW IT UNTIL I WAS BEHIND A CAR THE ONLY LIGHTS WERE ON WERE MY FOG LIGHTS. *TR

NHTSA ODI #10551200

79,000 miles · May 17, 2013
Electrical SystemEngineExterior Lighting

I WAS DRIVING ON THE HIGHWAY AT 60 MILES AN HOUR AND THE CAR COMPLETELY SHUT OFF. NO LIGHTS, NO ENGINE, NO POWER STEERING, NO DASH LIGHTS. THE CAR WENT COMPLETELY DEAD. I PULLED OVER AND LET THE CAR REST AND THEN IT STARTED UP AGAIN. I NOTICED THE SECOND TIME IT HAPPENED WHEN I TOOK MY FOOT OFF THE ACCELERATOR. I TOOK IT TO ARBO…

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I WAS DRIVING ON THE HIGHWAY AT 60 MILES AN HOUR AND THE CAR COMPLETELY SHUT OFF. NO LIGHTS, NO ENGINE, NO POWER STEERING, NO DASH LIGHTS. THE CAR WENT COMPLETELY DEAD. I PULLED OVER AND LET THE CAR REST AND THEN IT STARTED UP AGAIN. I NOTICED THE SECOND TIME IT HAPPENED WHEN I TOOK MY FOOT OFF THE ACCELERATOR. I TOOK IT TO ARBORMOTION IN ANN ARBOR MI AND THEY TOLD ME A CODE CAME UP AND SOME PART HAD TO BE CLEANED. WHEN I TOOK MY FOOT OFF THE ACCELERATOR THERE WAS NOT ENOUGH AIR GOING THROUGH THE PART TO ALLOW GAS TO FLOW. THEY FIXED THE PART AND A MONTH LATER, THE SAME THING HAPPENED ON THE HIGHWAY ONLY THIS TIME HOWEVER, UNLIKE THE FIRST TIME, JUST THE LIGHTS STAYED ON. I WENT TO THE SAME SHOP AND THEY SAID IT WAS ANOTHER CODE. I COULD HAVE BEEN KILLED ON THE HIGHWAY. THIS SHOULD NOT HAVE HAPPENED. *TR

NHTSA ODI #10512481

111,440 miles · Mar 3, 2013
Electrical SystemExterior Lighting

FRONT LIGHTS GO OFF GOT A TICKET FOR THAT REASON AND ONLY THRU THAT TICKET DID I KNOW THAT THE LIGHTS GO OFF IT HAPPENS ONCE IN A WHILE AND WHEN SO I HAVE TO GO TO SIDE OF THE ROAD AND TURN CAR OFF AND TURN ON AGAIN, WONT HAPPEN FOR A PERIOD AND THEN SURPRISE IT HAPPENS AGAIN.WE BOUGHT THE CAR USED AND WE DONT KNOW IF THERE IS A…

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FRONT LIGHTS GO OFF GOT A TICKET FOR THAT REASON AND ONLY THRU THAT TICKET DID I KNOW THAT THE LIGHTS GO OFF IT HAPPENS ONCE IN A WHILE AND WHEN SO I HAVE TO GO TO SIDE OF THE ROAD AND TURN CAR OFF AND TURN ON AGAIN, WONT HAPPEN FOR A PERIOD AND THEN SURPRISE IT HAPPENS AGAIN.WE BOUGHT THE CAR USED AND WE DONT KNOW IF THERE IS ANY RECALLS IT MIGHT NOT HAVE BEEN TAKEN CARE OF. *TR

NHTSA ODI #10501108

144,010 miles · Dec 28, 2012
Electrical SystemEngineExterior Lighting

LAST NIGHT MY 2004 VOLVO XC90 LEFT ME ON THE SIDE OF THE ROAD INTERSTATE 88 NEAR ROCK FALLS, IL WEATHER 7:00 PM 28 HUMIDITY: 73% WIND: NNE DEW POINT: 22 PRESSURE: 30.16 IN BONE DRY WHILE DRIVING 65MPH FELT A "THUMP" IN THE FRONT END, FOLLOWED BY A SPLIT SECOND WHERE ALL DASHBOARD LIGHTS, WENT BLACK. WHILE TRYING TO PUSH THE…

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LAST NIGHT MY 2004 VOLVO XC90 LEFT ME ON THE SIDE OF THE ROAD INTERSTATE 88 NEAR ROCK FALLS, IL WEATHER 7:00 PM 28 HUMIDITY: 73% WIND: NNE DEW POINT: 22 PRESSURE: 30.16 IN BONE DRY WHILE DRIVING 65MPH FELT A "THUMP" IN THE FRONT END, FOLLOWED BY A SPLIT SECOND WHERE ALL DASHBOARD LIGHTS, WENT BLACK. WHILE TRYING TO PUSH THE GAS PEDAL THE CAR WOULD NOT ACCELERATE. THEN NORMAL FUNCTION RESUMED. A MINUTE OR TWO LATER, SAME THING AND ALL LIGHTS INTERNALLY COMPLETELY WENT OUT, I PULLED OVER IMMEDIATELY AND TURNED THE CAR OFF. HAZARD LIGHTS COULD NOT BE TURNED ON. AFTER CALLING FOR A TOW TRUCK, AND WAITING ABOUT 45 MINUTES I RESTARTED IT. THERE WERE 2 MESSAGES ON THE DASH, THE YELLOW EXCLAMATION POINT DASHBOARD ICON/ALERT LIT UP, A SERVICE MESSAGE FLASHED REFERRING TO THE ANTI-LOCK BRAKE FAILURE, THE SRS NEEDED URGENT ATTENTION. I PURCHASED THIS VEHICLE IN EARLY NOVEMBER 2012 I CALLED THE CLOSEST VOLVO DEALERSHIP AND WAS TOLD THERE WERE NO OPEN RECALLS AND THEY HAD TO HAVE THE VEHICLE FOR DIAGNOSIS BECAUSE OF THE DIFFERENT SYMPTOMS I REPORTED NOT A SINGLE MENTION OF NHTSA DEFECT INVESTIGATIONS FOR THE 2004 VOLVO XC90 THAT SEEMS SPECIFICALLY RELATED TO MY SYMPTOMS EXPERIENCED. FROM: ERICA HENRY [MAILTO:[XXX]] SENT: FRIDAY, DECEMBER 28, 2012 11:55 AM TO:[XXX] SUBJECT: RE: SERVICE REQUEST - YES I WOULD LIKE TO MAKE AN APPOINTMENT FOR JAN 10TH. THERE ARE NO OPEN RECALLS ON YOUR VEHICLE. BECAUSE OF THE DIFFERENT SYMPTOMS THAT YOU EXPERIENCED, WE REALLY NEED TO HAVE THE CAR HERE TO PERFORM A DIAGNOSIS. THERE SHOULD HAVE BEEN SOME TROUBLE CODES STORED IN THE SYSTEM, AND THOSE WILL HELP MY TECHNICIAN FURTHER DIAGNOSE THE PROBLEM. IF YOU'D LIKE TO SCHEDULE STILL PLEASE LET ME KNOW. [XXX], SERVICE ADVISOR -[XXX]WORLD AUTO DIRECT LINE 815-991-2770 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10490370

88,013 miles · Oct 23, 2012
Electrical SystemElectronic Stability Control (esc)Exterior Lighting

WHILE DRIVING BETWEEN 65 AND 70 MILES ON A MAJOR INTERSTATE MY 2004 VOLVO XC 90 HAS A SEVERE "THUMP" IN THE FRONT END, WHICH IS THEN FOLLOWED BY A VERY BRIEF (SPLIT SECOND) INTERNAL (MEANING ALL DASHBOARD LIGHTS, HI-FI, DOME LIGHTS, RADIO AIR CONDITION, OIL GAGE, FUEL GAGE CLOCK ) POWER FAILURE. WHILE TRYING TO PUSH THE GAS THE …

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WHILE DRIVING BETWEEN 65 AND 70 MILES ON A MAJOR INTERSTATE MY 2004 VOLVO XC 90 HAS A SEVERE "THUMP" IN THE FRONT END, WHICH IS THEN FOLLOWED BY A VERY BRIEF (SPLIT SECOND) INTERNAL (MEANING ALL DASHBOARD LIGHTS, HI-FI, DOME LIGHTS, RADIO AIR CONDITION, OIL GAGE, FUEL GAGE CLOCK ) POWER FAILURE. WHILE TRYING TO PUSH THE GAS THE CAR WOULD NOT ACCELERATE. AT FIRST I HIT SOMETHING ON THE HIGHWAY. A MINUTE OR TWO LATER THE "THUMP" WAS HARDER AND THE LIGHTS INTERNALLY COMPLETELY WENT OUT, HAZARD LIGHTS COULD NOT BE TURNED ON, BLINKERS COULD NOT BE SWITCHED ON, HI-FI WENT OUT, THE DOOR LOCKS WOULD NOT WORK, THE WINDSHIELD WIPERS WOULD NOT CUT ON OR THE ELECTRIC WINDOWS. I PULLED OVER IMMEDIATELY AND TURNED THE CAR OFF, WAITED 10 MINUTES AND RESTARTED IT. THERE WERE 3 MESSAGES ON THE DASH, THE YELLOW EXCLAMATION POINT DASHBOARD ICON/ALERT LIT UP, A SERVICE MESSAGE FLASHED REFERRING TO THE ANTI-LOCK BRAKE FAILURE, THE SRS NEEDED TO BE CHECKED, AND CHECK ENGINE. THE NEXT DAY I TOOK IT TO A VOLVO DEALERSHIP, THEY COULDN'T DIAGNOSE THE PROBLEM. THEY ASSURED ME THAT THE CAR WAS OK TO DRIVE. FOUR DAYS LATER THE PROBLEM STARTS AGAIN. SO AFTER DOING A LITTLE RESEARCH I FIND OUT THAT THIS IS A COMMON OCCURRENCE ON THE VOLVO XC 90 AND THERE WAS AN INVESTIGATION ON THIS SAME ISSUE IN NOVEMBER 2010 IN WHICH VOLVO IS FULLY AWARE OF AND "ACKNOWLEDGES 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, THE DEVICE THAT CONTROLS MANY OF THE VEHICLES ELECTRICAL FUNCTIONS INCLUDING WIPER OPERATION, LIGHTING, AND TRANSMISSION OPERATION. IF THE WATER REACHES THE CENTRAL ELECTRONIC MODULE CONNECTOR ELECTRICAL FAULTS MAY RESULT." THIS IS A $1200.00 REPAIR WHICH VOLVO SHOULD PAY. *TR

NHTSA ODI #10482003

120,000 miles · Jul 31, 2012
Exterior Lighting

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH AT NIGHT, THE HEADLIGHTS WERE ACTIVATED AND SUDDENLY FAILED TO ILLUMINATE. IN ADDITION, THE LOW BEAM WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT ACTIVATED THE FOG LIGHTS IN ORDER TO CONTINUE DRIVING. THE VEHI…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH AT NIGHT, THE HEADLIGHTS WERE ACTIVATED AND SUDDENLY FAILED TO ILLUMINATE. IN ADDITION, THE LOW BEAM WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT ACTIVATED THE FOG LIGHTS IN ORDER TO CONTINUE DRIVING. THE VEHICLE HAD NOT BEEN DIAGNOSED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.

NHTSA ODI #10468389

122,500 miles · Jun 17, 2012
Air BagsElectrical SystemExterior Lighting

DRIVING FROM PHX TO TUS AT 75 MI OUT OF PHX AT ABOUT 2200HRS. THE CAR COMPLETELY FAILED FOR FRACTION OF A SECOND THEN RESUMED NORMAL OPERATION UNTIL ARRIVING AT DESTINATION 10 MI. LATER. THE SECOND TIME A WEEK LATER WAS TRAVELING TO PHX AT 1800 HRS. 70MI OUT OF TUS. THE CAR FAILED LIKE THE FIRST TIME THEN A FEW SECONDS LATER DID…

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DRIVING FROM PHX TO TUS AT 75 MI OUT OF PHX AT ABOUT 2200HRS. THE CAR COMPLETELY FAILED FOR FRACTION OF A SECOND THEN RESUMED NORMAL OPERATION UNTIL ARRIVING AT DESTINATION 10 MI. LATER. THE SECOND TIME A WEEK LATER WAS TRAVELING TO PHX AT 1800 HRS. 70MI OUT OF TUS. THE CAR FAILED LIKE THE FIRST TIME THEN A FEW SECONDS LATER DID IT AGAIN REACHED DESTINATION ABOUT 15MI. LATER. WHEN THIS HAPPENS THE LIGHTS, RADIO, WINDOWS, DASH LIGHT AND GAUGES ALL STOP WORKING THE MESS. COMES ON ABS,SRS. ITS HAPPENED 5 OR 6 TIMES NOW WITH THE WORST BEING YESTERDAY 16 JUNE 2012 . I GOT OFF LOOP 202 AND PULLED IN A PARKING LOT AND SHUT DOWN THE CAR AND THEN ATTEMPTED TO RESTART 4 TIMES BEFORE IT RESTARTED. THE A/C,WINDOWS, LIGHTS, GAUGES,TURN SIGNALS ALL FAILED. THE MESS. ABS, SRS, CHECK ENGINE CAME ON. I DROVE ABOUT 5 MI TO DESTINATION. I'M NOW SCARED TO DRIVE IT IF THE SRS, ABS WARNING ARE ON ARE THEY WORKING? IF IN AN ACCIDENT WILL THE PASSENGERS AND DRIVER BE PROTECTED ? *TR

NHTSA ODI #10462001

57,675 miles · Oct 24, 2011
Exterior Lighting

HEADLIGHTS GO ON AND OFF, DON'T WORK CONSISTENTLY. SOMETIMES BOTH WORK, SOMETIMES 1 WORKS, SOMETIMES NEITHER WORK. DEALER WANTED ME TO REPLACE BULBS BUT AT ALMOST 200.00 PER BULB I THINK THE PROBLEM IS SOMEWHERE ELSE SINCE THE BULBS DO WORK SOMETIMES. *TR

NHTSA ODI #10432608

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

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

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.