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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

Fuel System, Gasoline complaints

40 reports
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30,000 miles · Nov 9, 2022
Fuel System, Gasoline

The contact owns a 2004 Volvo XC90. The contact stated that after refueling the vehicle, his wife noticed an abnormally strong gasoline odor. The contact's wife was able to continue driving the vehicle; however, the failure would return after refueling or on rainy days. The contact related the failure to NHTSA Campaign Number: 0…

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The contact owns a 2004 Volvo XC90. The contact stated that after refueling the vehicle, his wife noticed an abnormally strong gasoline odor. The contact's wife was able to continue driving the vehicle; however, the failure would return after refueling or on rainy days. The contact related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline) however, the VIN was not included. The dealer and the manufacturer were notified of the failure and informed the contact that they could not assist as the VIN was not under recall. The vehicle was not diagnosed or repaired. The failure mileage was approximately 30,000.

NHTSA ODI #11492882

212,000 miles · Oct 3, 2022
Fuel System, Gasoline

The contact owns a 2004 Volvo XC90. The contact stated that after his wife started the vehicle, she smelled the odor of gasoline. The contact had been advised by his wife that the vehicle was taking longer to start up and sometimes required two or three attempts to start the vehicle. The contact stated no warning light was illum…

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The contact owns a 2004 Volvo XC90. The contact stated that after his wife started the vehicle, she smelled the odor of gasoline. The contact had been advised by his wife that the vehicle was taking longer to start up and sometimes required two or three attempts to start the vehicle. The contact stated no warning light was illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic to be diagnosed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline). The failure mileage was approximately 212,000.

NHTSA ODI #11487737

114,000 miles · Nov 2, 2016
Fuel System, Gasoline

THERE IS A VERY STRONG SMELL OF GAS WHILE DRIVING AT ALL SPEEDS. THE SMELL GETS WORSE ON THE RIGHT HAND REAR PASSENGER SEAT WHEN PARKED. I TOOK IT IN FOR DIAGNOSIS AND WAS TOLD THERE IS A LEAK ON TOP OF THE FUEL PUMP. I CALLED TO VOLVO OF NORTH AMERICA SEE IF THERE IS A RECALL. THE LADY I TALKED TO WAS VERY NICE AND SEAMED KN…

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THERE IS A VERY STRONG SMELL OF GAS WHILE DRIVING AT ALL SPEEDS. THE SMELL GETS WORSE ON THE RIGHT HAND REAR PASSENGER SEAT WHEN PARKED. I TOOK IT IN FOR DIAGNOSIS AND WAS TOLD THERE IS A LEAK ON TOP OF THE FUEL PUMP. I CALLED TO VOLVO OF NORTH AMERICA SEE IF THERE IS A RECALL. THE LADY I TALKED TO WAS VERY NICE AND SEAMED KNEW EXACTLY WHAT I WAS TALKING ABOUT. IF THIS A PROBLEM WHY IS THERE NO RECALL IN ALL STATES IN USA. *TR

NHTSA ODI #10923903

132,000 miles · Jul 29, 2016
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING, THERE WAS A STRONG ODOR OF FUEL IN THE VEHICLE. THE CONTACT NOTICED FUEL LEAKING ONTO THE GROUND. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. …

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING, THERE WAS A STRONG ODOR OF FUEL IN THE VEHICLE. THE CONTACT NOTICED FUEL LEAKING ONTO THE GROUND. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM). THE FAILURE MILEAGE WAS 132,000.

NHTSA ODI #10891587

Mileage unknown · Mar 10, 2015
Fuel System, Gasoline

2004 VOLVO XC90. CONSUMER WRITES IN REGARDS TO A BROKEN FUEL PUMP AND LEAKING GAS. *SMD THE CONSUMER NOTICED A STRONG GAS SMELL IN THE GARAGE. THE CONSUMER DISCOVERED RECALL # 09V483000. HOWEVER, HE WAS NEVER INFORMED. *JB

NHTSA ODI #10677140

109,581 miles · Dec 5, 2014
Fuel System, Gasoline

SMELLED GASOLINE, TOOK IT TO A SHOP, THEY FOUND FUEL PUMP CRACKED, REPLACED FUEL PUMP. THEN WE FOUND OUT THE WAS A RECALL IN SOUTHERN STATES FOR THIS PROBLEM SPECIFICALLY. WE LIVE IN THE NEW ENGLAND AREA AND WAS TOLD IT WOULD NOT BE CONSIDERED UNDER THE RECALL. I FEEL COMPLETELY WRONGED IN THIS SITUATION. THE RECALL WAS SPECIFIC…

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SMELLED GASOLINE, TOOK IT TO A SHOP, THEY FOUND FUEL PUMP CRACKED, REPLACED FUEL PUMP. THEN WE FOUND OUT THE WAS A RECALL IN SOUTHERN STATES FOR THIS PROBLEM SPECIFICALLY. WE LIVE IN THE NEW ENGLAND AREA AND WAS TOLD IT WOULD NOT BE CONSIDERED UNDER THE RECALL. I FEEL COMPLETELY WRONGED IN THIS SITUATION. THE RECALL WAS SPECIFIC TO HEAT CYCLING. NO WERE IN THE US IS THIS MORE APPARENT THAN NEW ENGLAND. *TR

NHTSA ODI #10662428

152,105 miles · Jun 25, 2014
Fuel System, GasolineVehicle Speed Control

UPON LEAVING OUT FOR THE DAY VEHICLE HESITATED SOMEWHAT WHEN I WOULD ACCELERATE ON GAS PEDAL. AFTER DRIVING FOR ONLY 5 MLS. VEHICLE STARTED SPUTTERING, I THOUGHT MAYBE I SHOULD STOP AND GET GAS THAT WOULD SOLVE THE PROBLEM BUT NO THE PROBLEM CONTINUED AND GOT WORSE, AS LONG AS I WAS JUST COASTING IT WAS OK, BUT UPON ACCELERATING…

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UPON LEAVING OUT FOR THE DAY VEHICLE HESITATED SOMEWHAT WHEN I WOULD ACCELERATE ON GAS PEDAL. AFTER DRIVING FOR ONLY 5 MLS. VEHICLE STARTED SPUTTERING, I THOUGHT MAYBE I SHOULD STOP AND GET GAS THAT WOULD SOLVE THE PROBLEM BUT NO THE PROBLEM CONTINUED AND GOT WORSE, AS LONG AS I WAS JUST COASTING IT WAS OK, BUT UPON ACCELERATING IS WHEN IT FELT LIKE IT WAS ABOUT TO STALL AND THERE WAS ALSO FUEL SMELL WHEN ACCELERATING. THE SPUTTERING & SHAKING AND ROUGH SOUND WORSEN AS WELL. I SPOKE WITH AN AUTO REPAIRMAN AND HE INFORMED ME OF THE VEHICLES RECALLS ON FUEL SYSTEM AND THAT IT WAS MOST DEFINITELY WHAT MY SITUATION WAS WITH MY VOLVO. *TR

NHTSA ODI #10606011

189,000 miles · Jun 24, 2014
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT FUEL FUMES WERE EMITTING FROM THE VEHICLE INTERMITTENTLY. THE CONTACT NOTIFIED THE DEALER OF THE SAFETY CONCERN AND WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS TO BE INSPECTED BY AN A…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT FUEL FUMES WERE EMITTING FROM THE VEHICLE INTERMITTENTLY. THE CONTACT NOTIFIED THE DEALER OF THE SAFETY CONCERN AND WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS TO BE INSPECTED BY AN AUTHORIZED DEALER. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 189,000.

NHTSA ODI #10605716

Mileage unknown · Sep 2, 2013
Fuel System, Gasoline

FOR ABOUT 2 MONTHS NOW I HAVE BEEN SMELLING LOUD ODORS OF GAS/FUEL INSIDE THE CAR COMING FROM THE LEFT SIDE OF MY 2004 VOLVO XC90. THE SMELL IS BECOMING UNBEARABLE CAUSING HEADACHES. I HAD MY HUSBAND LOOK UNDER MY CAR TO SEE IF THERE WAS AN OBVIOUS LEAK. HE NOTICED THAT THE SIDE OF THE FUEL TANK WAS WET, HE WIPED THE TANK OFF MA…

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FOR ABOUT 2 MONTHS NOW I HAVE BEEN SMELLING LOUD ODORS OF GAS/FUEL INSIDE THE CAR COMING FROM THE LEFT SIDE OF MY 2004 VOLVO XC90. THE SMELL IS BECOMING UNBEARABLE CAUSING HEADACHES. I HAD MY HUSBAND LOOK UNDER MY CAR TO SEE IF THERE WAS AN OBVIOUS LEAK. HE NOTICED THAT THE SIDE OF THE FUEL TANK WAS WET, HE WIPED THE TANK OFF MAKING IT DRY DROVE THE CAR AROUND A COUPLE BLOCKS PARKED IT & CHECKED UNDER THE CAR AGAIN, THE TANK WAS WET ON THE SIDE OF THE FUEL TANK AGAIN WITH FUEL LEAKING FROM SOMEWHERE. AGAIN NO OBVIOUS SPOT OR LOCATION OF THE LEAK WAS SEEN & ITS NOT A BAD LEAK WHEREAS YOU CAN SEE IT DRIPPING, BUT IT IS LEAKING FROM SOMEWHERE. MY CAR IS ALSO EXPERIENCING A SLOW SLUGGISH START IN MY OPINION DUE TO THE FUEL ISSUE. I'VE DONE SOME RESEARCH & FOUND OUT THIS IS A COMMON PROBLEM WITH CERTAIN VOLVO'S (01-05 S80, 01-04 V70/S60/XC70, 03-05 XC90) WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITION FOR EXAMPLE HOT CLIMATES & TEMPERATURES. WHEN VOLVO VEHICLES ARE EXPOSED TO THESE CONDITIONS IN COMBINATION WITH FUEL QUALITY THERE'S A HIGHER/GREATER CHANCE THAT THE FUEL PUMP CAN DEVELOP/BECOME CRACKED, DAMAGED, OR PINCHED IN THE FUEL PUMP FLANGE OF WHICH CAUSES AN AIR LEAK IN THE FUEL VAPOR SYSTEM. ALSO 2004 XC90 MODELS HAS THE MOST OVERALL COMPLAINTS. I NEED MORE INFO ON HOW & WHERE VOLVO CAN FIX THIS ISSUE BECAUSE AGAIN UPON RESEARCHING THIS VOLVO HAS DONE A MAJOR RECALL FOR A FAULTY FUEL PUMP OF WHICH INCLUDES MY CAR BASED OFF INFO I HAVE FOUND. HOPEFULLY I WILL BE CONTACTED IMMEDIATELY BECAUSE FROM WHAT I UNDERSTAND THIS ISSUE WILL ONLY BECOME WORSE & IN SOME CASES UPON STARTING THE IGNITION CAN STRIKE OR CAUSE A FIRE. THANKS. *JS

NHTSA ODI #10538395

110,000 miles · Aug 15, 2013
Fuel System, Gasoline

BACK IN SEPTEMBER OF 2012 MY CAR STARTED STALLING OFF AND ON. IT CAN HAPPEN SEVERAL TIMES A DAY OR ONCE A WEEK OR ONCE A MONTH. I HAVE PUT THOUSANDS OF DOLLARS INTO TRYING TO REMEDY THE PROBLEM WITH NO SUCCESS. I FINALLY TOOK MY CAR TO THE VOLVO DEALERSHIP WHERE I PURCHASED MY CAR IN 2003. THEY INFORMED ME THAT THE PROBLEM IS RE…

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BACK IN SEPTEMBER OF 2012 MY CAR STARTED STALLING OFF AND ON. IT CAN HAPPEN SEVERAL TIMES A DAY OR ONCE A WEEK OR ONCE A MONTH. I HAVE PUT THOUSANDS OF DOLLARS INTO TRYING TO REMEDY THE PROBLEM WITH NO SUCCESS. I FINALLY TOOK MY CAR TO THE VOLVO DEALERSHIP WHERE I PURCHASED MY CAR IN 2003. THEY INFORMED ME THAT THE PROBLEM IS RELATED TO A DEFECTIVE FUEL PUMP THAT VOLVO WAS REQUIRED BY THE NHTSA TO NOTIFY OWNERS OF MY SAME VEHICLE, (AS WELL AS MANY OTHER MODEL VOLVOS), THAT THE WARRANTY WAS EXTENDED TO 10 YEARS/150,000 MILES. I NEVER RECEIVED THAT NOTICE FROM VOLVO. I HAVE HAD THE SAME ADDRESS SINCE I PURCHASED THE CAR SO THERE IS NO EXCUSE WHY I SHOULD NOT HAVE RECEIVED IT. IF I HAD KNOWN THAT THIS PROBLEM EXISTED I WOULD HAVE CONSIDERED HAVING THE FUEL PUMP CHECKED OUT AND SAVED MYSELF THOUSANDS OF DOLLARS. THE STALLING ISSUE HAS BEEN VERY DANGEROUS, AND ALMOST COST ME AND MY FAMILY OUR LIVES. AT TIMES IT HAS STALLED IN THE MIDDLE OF INTERSECTIONS AND I'VE COME CLOSE TO BEING REAR ENDED AND HIT ON THE PASSENGER OR DRIVER SIDE DOOR. MOST RECENTLY IT STALLED AFTER I STOPPED AT A T IN A HWY AND WAS TRYING TO TURN LEFT. IT LEFT ME IN THE MIDDLE OF A TWO LANE HWY, ON A BLIND CURVE, THAT PEOPLE COMING EITHER DIRECTION COULD NOT SEE MY CAR. I COULD HAVE BEEN HIT BY A CAR COMING AT LEAST 55 MPH AND IT COULD HAVE TURNED INTO A VERY NASTY ACCIDENT. ANGELS WHERE WATCHING OVER ME AND MY FAMILY THAT DAY. I HOPE THAT THE NHTSA LOOKS INTO WHY VOLVO DID NOT FOLLOW THROUGH ON THEIR AGREEMENT TO NOTIFY ALL OWNERS OF VEHICLES INVOLVED IN THE EXTENDED WARRANTY. I PURCHASED A VOLVO MAINLY BECAUSE THEY HAVE A REPUTATION OF BEING A SAFE CAR BUT LATELY IT HASN'T BEEN. *TR

NHTSA ODI #10535536

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.