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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132,100 miles · Dec 9, 2011

Fuel System, Gasoline

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LAST SUMMER WE PURCHASE A 2004 VOLVO XC 90 AND AFTER REVIEW OF CARFAX NOTICE WE SAW A RECALL ON THE FUEL PUMP. WE TOOK IT IN FOR THE RECALL AND VOLVO OF NEW BERN, NC CHANGE OUT THE PART. I HAVE NOTICED A STRONG SMELL OF GAS AND THE VOLVO IS LEAKING OUT FUEL FROM WHERE THE FUEL TANK IS LOCATED UNDER THE PASSENGER SEAT ON THE DRIVER SIDE. WE HAVE NOTIFIED BOTH VOLVO HOME OFFICE ASWELL AS VOLVO OF NEW BERN WITH NO LUCK. WE WERE TOLD IT SHOULD NOT BE LEAKING. AND ON TOP OF THAT THE FRONT PASSENGER DOOR WHILE DRIVING JUST POP OPEN AND WE HAVE TO KEEP SLAMMING IT TO GET IT TO STAY CLOSED, AND WELL AS THE PASSENGER DOOR ON THE RIGHT SIDE WILL NOT OPEN FROM THE INSIDE. *TR

NHTSA ODI #10439136

86,000 miles · Oct 30, 2011

Fuel System, Gasoline

FUEL LINES FROM THE TANK TO THE ENGINE COMPONENT STARTED TO LEAK AND A FUEL SMELL GOT THE ATTENTION OF A PASSERBY WHICH MADE ME AWARE OF THE PROBLEM AND MADE ME TURN OFF MY VEHICLE. *TR

NHTSA ODI #10433576

63,500 miles · Nov 16, 2010

Fuel System, Gasoline

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MY VEHICLE WAS RECALLED FOR A FUEL PUMP ISSUE BY THE NHTSA. IN A LETTER DATED 9/13/2010, VOLVO CARS OF NORTH AMERICA OUTLINED THE REASON FOR THE RECALL AND SPECIFICALLY ADVISED: PLEASE SCHEDULE AN APPOINTMENT AT YOUR LOCAL AUTHORIZED VOLVO RETAILER AS SOON AS POSSIBLE TO HAVE THIS IMPORTANT SAFETY RECALL PERFORMED AT NO CHARGE. I CONTACTED MY VOLVO RETAILER AND WAS SPECIFICALLY ADVISED TO BRING MY CAR IN WITH AS LITTLE FUEL AS POSSIBLE BECAUSE THE TECHNICIANS WOULD HAVE TO DRAIN THE TANKS TO CONDUCT THE REPAIR. I FOLLOWED THIS ORDER TO THE LETTER AND DROPPED MY VEHICLE OFF FOR THE "NO CHARGE" RECALL REPAIR. AT DROP OFF, I HAD ALSO SPECIFICALLY REQUESTED THE SERVICE DEPARTMENT TO CONTACT ME WITH AN ESTIMATE FOR A REPAIR TO THE THIRD ROW SEAT AND RIGHT TURN SIGNAL BEFORE CORRECTING. THE SERVICE DEPARTMENT DID CALL WITH THE ESTIMATE FOR THE SEAT REPAIR AND I AGREED TO THE $100 CHARGE. IN THE AFTERNOON WHEN MY HUSBAND PICKED UP MY VOLVO, I HAD BEEN CHARGED $53.72 FOR FUEL THAT I NEVER AUTHORIZED. WHEN I CALLED TO COMPLAIN, I WAS TOLD THE VEHICLE HAD TO BE FUELED IN ORDER TO CHECK THE REPAIR. IF THAT WAS THE CASE, THEN WHY WAS I TOLD TO BRING IT IN EMPTY AND NEVER TOLD THAT VOLVO WOULD TAKE THE LIBERTY TO FILL IT UP WITHOUT MY APPROVAL? $54 DOLLARS IS NOT THE ISSUE--THE ISSUE IS THAT VOLVO WANTED TO MAKE AN EASY REPAIR WITH A CAR THEY DID NOT HAVE TO DRAIN GAS FROM THE TANK AND STORE. I COULD HAVE BROUGHT MY CAR IN WITH A FULL TANK AND IT WAS VOLVO'S RESPONSIBILITY TO REPAIR MY CAR "AT NO CHARGE". INSTEAD, VOLVO SHIFTED THEIR BURDEN TO ME AND THEN MADE ME PAY TO MAKE IT EASIER FOR THEIR REPAIR TECHNICIANS. *TR

NHTSA ODI #10366489

71,779 miles · Jul 26, 2010

Fuel System, Gasoline

APPOINTMENT SET WITH VOLVO DEALER ON 07/26/2010 FOR FUEL PUMP RECALL. AFTER THE SERVICE I EXPERIENCED EVEN MORE STRONGER GASOLINE ODOR WHILE DRIVING. FELT NAUSEA I HAD TO HAVE ALL WINDOWS DOWN. CALLED THE DEALER'S SERVICE DEPARTMENT IN THE SAME DAY AFTERNOON, I WAS TOLD THAT THE ODOR SHOULD DISSIPATE WITHIN 2 WEEKS. IS IT NO…

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NHTSA ODI #10345549

Mileage unknown · Mar 1, 2010

Fuel System, Gasoline

RECALL 2004 VOLVO XC90 FUEL PUMP *BF THE CONSUMER STATED SHE EXPERIENCED THE PROBLEM BACK IN OCTOBER 2008. THERE WAS A HORRIBLE GAS SMELL COMING FROM THE VEHICLE. THE DEALER WAS UNABLE TO DIAGNOSE THE PROBLEM THE FIRST TIME. THE CONSUMER IS SEEKING REIMBURSEMENT. *JB

NHTSA ODI #10313205

32,400 miles · Jan 29, 2010

EquipmentFuel System, GasolineLatches/locks/linkages

DRIVING ON 210-WEST, MY CAR LOST POWER WITHOUT WARNING. THE FUEL PUMP HAD BEEN REPLACED ON JAN. 26, 2010, TO CORRECT THE STRONG SMELL OF GASOLINE INSIDE AND OUTSIDE OF THE CAR. OTHER PROBLEMS HAVE BEEN REPLACING THE BRAKE PADS TWICE, REPLACING THE ABS, FAULTY GPS AND CD PLAYER, FRONT PASSENGER DOOR AUTOMATIC LOCK NEEDS MOTOR R…

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NHTSA ODI #10303222

75,000 miles · Jan 23, 2010

Fuel System, Gasoline

I OWN A 2004 VOLVO XC 90 SUV. I BEGAN SMELLING STRONG GASOLINE FUMES/ODORS INSIDE THE VEHICLE AND OUTSIDE THE VEHICLE. THIS SMELL IS GETTING STRONGER AND IS STARTING TO CAUSE HEADACHES AND EYE AND NOSE IRRITATION TO ME AND PASSENGERS. IT APPEARS TO BE A HUGE PROBLEM WITH THIS MODEL BECAUSE MANY PEOPLE HAVE EXPRESSED THE SAME CO…

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NHTSA ODI #10302017

75,000 miles · Dec 10, 2009

Fuel System, Gasoline

I OWN A 2004 VOLVO XC90 AWD T6. THERE ALWAYS IS A STRONG ODOR OF FUEL OUTSIDE THE CAR AND SOMETIMES INSIDE THE CAR. THIS SMELL BEGAN IN SEPTEMBER 2009. I LIVE IN THE TAMPA AREA OF FLORIDA. *TR

NHTSA ODI #10295271

85,000 miles · Dec 1, 2009

Fuel System, Gasoline

2004 VOLVO XC90-STRONG ODOR OF GASOLINE IN GARAGE AND INSIDE OF VEHICLE. THE SMELL BECOMES STRONGER AFTER DRIVING AND FILLING UP. *TR

NHTSA ODI #10294128

84,239 miles · Nov 25, 2009

Fuel System, Gasoline

I HAVE HAD MY 2004 VOLVO XC90 FOR 2 YEARS, NO ISSUE UNTIL 3 WEEKS AGO STARTED SMELLING FUEL ODOR. 1 WEEK AGO, STARTED HAVING SLOW SLUGGISH ENGINE STARTS. I CHECKED UNDER VEHICLE NEAR GAS TANK AND NOTICED TANK WAS SATURATED WITH FUEL. NO REPAIRS TO VEHICLE AT THIS TIME, WAITING FOR RECALL. THIS APPEARS TO BE AN ISSUE WITH A …

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NHTSA ODI #10293572

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.