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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.

About this comparison →

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

What owners actually said

462 reports
98,003 miles · Feb 16, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE JERKED VIOLENTLY AND THE INSTRUMENT PANEL GAUGES FAILED. THE ENGINE WAS SHUT OFF AND THEN RESTARTED AFTER SEVERAL MINUTES. THE VEHICLE RESUMED NORMALLY FOR A SHORT PERIOD BEFORE THE FAILURE RECURRED. THE CONTACT STATED THE MALFUNCTION OCCURRE…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE JERKED VIOLENTLY AND THE INSTRUMENT PANEL GAUGES FAILED. THE ENGINE WAS SHUT OFF AND THEN RESTARTED AFTER SEVERAL MINUTES. THE VEHICLE RESUMED NORMALLY FOR A SHORT PERIOD BEFORE THE FAILURE RECURRED. THE CONTACT STATED THE MALFUNCTION OCCURRED AFTER DRIVING FOR APPROXIMATELY FIVE HOURS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FAULTY CEM UNIT WAS REPLACED. THE FAILURE MILEAGE WAS 98,003. UPDATED 3/21/11 *CN

NHTSA ODI #10382885

123,000 miles · Feb 15, 2011
Electrical System

CAR LOST ALL POWER. ALL DASHBOARD WENT OFF AND POWER STEERING WENT OUT WHILE DRIVING AT OVER 40 MILES AN HOUR ON THE HIGHWAY. THIS HAPPENED ON 4 DIFFERENT OCCASIONS. MILEAGE 123,000 2004 VOLVO XC90 T6. *TR

NHTSA ODI #10382839

107,000 miles · Feb 7, 2011
Unknown Or Other

ALL DASHLIGHTS WENT COMPLETELY BLACK, AND THE POWER STEERING WENT OUT WITH IT WHILE DRIVING DOWN THE FREEWAY (AT NIGHT). THIS HAPPENED ON THREE DIFFERENT OCCASIONS. VOLVO DEALER CLAIMED THEY "RESET" IT THE FIRST TWO FIXES AND THEN THE THIRD TIME REPLACED THE CEM, WHICH WAS A COUPLE THOUSAND DOLLAR FIX FOR ME. *LN

NHTSA ODI #10381022

108,540 miles · Jan 30, 2011
Electrical SystemPower TrainStructure

LIQUID (PROBABLY WATER) INSIDE THE FRAME OF VOLVO XC90 CAUSING ELECTRICAL ISSUES. *TR

NHTSA ODI #10379579

107,000 miles · Jan 23, 2011
Power Train

I HAVE A 2004 VOLVO XC90. AT APPROXIMATELY 52K MILES, THE XC90 1ST GENERATION TRANSMISSION WENT BAD AND HAD TO BE REPLACED. CARLSEN VOLVO (PALO ALTO, CA) AGREED TO COVER THE COST OF THE TRANSMISSION REPLACEMENT. I WAS VERY PLEASED WITH THE SERVICE AND WENT ON MY WAY. IN DECEMBER 2010 AT ~107,000K MILES, THE TRANSMISSION STARTED…

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I HAVE A 2004 VOLVO XC90. AT APPROXIMATELY 52K MILES, THE XC90 1ST GENERATION TRANSMISSION WENT BAD AND HAD TO BE REPLACED. CARLSEN VOLVO (PALO ALTO, CA) AGREED TO COVER THE COST OF THE TRANSMISSION REPLACEMENT. I WAS VERY PLEASED WITH THE SERVICE AND WENT ON MY WAY. IN DECEMBER 2010 AT ~107,000K MILES, THE TRANSMISSION STARTED TO HESITATE & FUNCTION ERRATICALLY WHILE DRIVING. WITHIN AFEW DAYS, THE CAR WAS PARKED AT MY HOME, AND WAS UNABLE TO ENGAGE IN FORWARD OR REVERSE. I TOWED THE CAR IN; IT WAS DIAGNOSED W/ INTERNAL TRANSMISSION PROBLEM. THE SERVICE REP SAID THAT SHE WOULD TALK TO THE FACTORY REP REGARDING COMPENSATION. THE DEALER REP CALLED VOLVO N.A. REP, WYATT, WHO OFFERED TO PAY FOR THE PARTS (~$3,500) BUT I WOULD HAVE TO PAY FOR THE LABOR(~$1,500). MY HUSBAND COUNTERED THAT WE WOULD LIKE THE WHOLE THING PAID FOR SINCE IT WAS WELL KNOWN FACTORY DEFECT. WHEN WYATT HEARD OF OUR COUNTER OFFER, HE NOT ONLY DENIED THIS, BUT SIMPLY STATED THAT THE DEAL WAS OFF THE TABLE, PERIOD. THE NEXT DAY, I RECONSIDERED AND ASKED THE SERVICE REP TO CALL WYATT AGAIN WITH OUR ACCEPTANCE OF THE INITIAL DEAL. WYATT REFUSED TO PUT THE DEAL BACK ON THE TABLE AND SAID WE SHOULD PAY FOR THE REPAIRS OURSELVES. THEN CALLED VOLVO CUSTOMER CARE WHO DOCUMENTED THE COMPLETE STORY,CONTACTED WYATT VIA EMAIL TO AGAIN. HOWEVER, WYATT REFUSED. APPARENTLY BECAUSE I HAVE CHOSEN IN THE PAST TO HAVE A PERSONAL MECHANIC SERVICE MY CAR, CHANGE THE OIL AND TIRES, ETC. I AM CONSIDERED TO BE A "DISLOYAL VOLVO CUSTOMER" AND THIS WAS A CONSIDERATION IN WYATT'S DECISION NOT TO PAY FOR MY TRANSMISSION, EVEN THOUGH IT IS A DEFECTIVE PART. AT THIS POINT, I HAD TO HAVE MY CAR BACK, AND TOLD CARLSEN TO REPLACE THE TRANSMISSION. CARLSEN OFFERED A 10% DISCOUNT OFF THE TOTAL PRICE. A VERY KIND GESTURE, HOWEVER, I HAD TO PAY $4,600 OUT OF POCKET FOR ANOTHER NEW TRANSMISSION FOR THIS CAR. IT'S WELL DOCUMENTED THAT THE 1ST AND 2ND GENERATION TRANSMISSIONS FOR THIS MODEL HAVE BEEN DEFECTIVE. I AM DISGUSTED. *LN

NHTSA ODI #10378346

48,000 miles · Jan 20, 2011
Wheels

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT TOOK THE VEHICLE TO HAVE THE TIRES REPLACED. THE FRONT RIGHT TIRE WAS REPLACED AND AIR CAME OUT OF THE TIRE. THE TECHNICIAN STATED THAT THERE WAS A CRACK IN THE RIM WHICH CAUSED THE TIRE TO LOSE AIR. THE DEALER STATED THAT THE RIM WAS NO LONGER UNDER WARRANTY. THE CURRENT AND FA…

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT TOOK THE VEHICLE TO HAVE THE TIRES REPLACED. THE FRONT RIGHT TIRE WAS REPLACED AND AIR CAME OUT OF THE TIRE. THE TECHNICIAN STATED THAT THERE WAS A CRACK IN THE RIM WHICH CAUSED THE TIRE TO LOSE AIR. THE DEALER STATED THAT THE RIM WAS NO LONGER UNDER WARRANTY. THE CURRENT AND FAILURE MILEAGES WERE 48,000.

NHTSA ODI #10378055

119,000 miles · Jan 13, 2011
Electrical SystemInjury

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT THE VEHICLE SHUT OFF AND BACK ON CAUSING A PAINFUL JERKING MOTION TO THE OCCUPANTS OF THE VEHICLE. THE CONTACT HURT HIS NECK AND SHOULDERS FROM THE DRASTIC JOLT THAT THE VEHICLE MADE. THE LIGHTS AND ALL POWER SHUT OFF AND THEN THEY IMMEDIATELY COME BACK ON. THE CONT…

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT THE VEHICLE SHUT OFF AND BACK ON CAUSING A PAINFUL JERKING MOTION TO THE OCCUPANTS OF THE VEHICLE. THE CONTACT HURT HIS NECK AND SHOULDERS FROM THE DRASTIC JOLT THAT THE VEHICLE MADE. THE LIGHTS AND ALL POWER SHUT OFF AND THEN THEY IMMEDIATELY COME BACK ON. THE CONTACT HAD TAKEN THE VEHICLE TO THE DEALER SEVERAL TIMES AND WAS TOLD THAT THEY COULD NOT FIND ANYTHING WRONG WITH THE VEHICLE. THE CONTACT ALSO STATED THAT THE FAILURE SEEMED TO HAPPEN EVERY 500 MILES AND WAS NOW HAPPENING MORE FREQUENTLY. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 80,000 AND THE FAILURE MILEAGE WAS 119,000.

NHTSA ODI #10376565

93,000 miles · Jan 2, 2011
Air BagsCrashInjury

MY HUSBAND HAD A 55MPH CRASH IN MY 2004 VOLVO XC90 ON THE FREEWAY. HE REAR ENDED ANOTHER DRIVER AT TOP SPEED, WAS SPUN AROUND SEVERAL TIMES ON THE FREEWAY AND ENDED UP FACING TRAFFIC. THE PASSENGER SIDE AIRBAG DEPLOYED, BUT THE DRIVER'S SIDE DID NOT. THE INSPECTOR FROM MY INSURANCE COMPANY SAID THERE WAS NOT REASON THE DRIVER…

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MY HUSBAND HAD A 55MPH CRASH IN MY 2004 VOLVO XC90 ON THE FREEWAY. HE REAR ENDED ANOTHER DRIVER AT TOP SPEED, WAS SPUN AROUND SEVERAL TIMES ON THE FREEWAY AND ENDED UP FACING TRAFFIC. THE PASSENGER SIDE AIRBAG DEPLOYED, BUT THE DRIVER'S SIDE DID NOT. THE INSPECTOR FROM MY INSURANCE COMPANY SAID THERE WAS NOT REASON THE DRIVER'S SIDE AIRBAG DID NOT DEPLOY AT THAT SPEED, OTHER THAN A DEFECT, AS FAR AS HE WAS CONCERNED. I CONTACTED VOLVO AND WAS BASICALLY GIVEN THE RUN AROUND ABOUT HOW THE AIRBAG SHOULD NOT HAVE DEPLOYED AND THAT THIS WAS PERFECTLY OKAY. I WOULD LIKE AN INVESTIGATION ESPECIALLY SINCE MY CEM SYSTEM WAS NOT OPERATING PROPERLY PRIOR TO THE ACCIDENT. I HAD AIRBAG WARNING, BRAKE FAILURE, ETC., AND THE DEALER TOLD ME A YEAR AGO THE CEM SYSTEM WAS NOT WORKING PROPERLY AND NEEDED TO BE REPAIRED AT $1300, WHICH I WAS NOT WILLING TO PAY. *TR

NHTSA ODI #10373782

115,089 miles · Dec 24, 2010
Electrical System

DURING LONG DURATIONS(>4HRS) OF DRIVING MY 2004 VOLVO XC90, IT SEEMS TO HAVE ELECTRICAL PROBLEMS THAT HAVE CAUSED ME AND THE PASSENGERS TO BE PUT INTO DANGEROUS SITUATIONS. FOR EXAMPLE, DRIVING ON A LONG TRIP WITH THE CRUISE CONTROL ENABLED AND TRYING TO ACCELERATE UP A HILL AND SUDDENLY THE CAR WILL GO INTO AN ENGINE PROTECTIO…

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DURING LONG DURATIONS(>4HRS) OF DRIVING MY 2004 VOLVO XC90, IT SEEMS TO HAVE ELECTRICAL PROBLEMS THAT HAVE CAUSED ME AND THE PASSENGERS TO BE PUT INTO DANGEROUS SITUATIONS. FOR EXAMPLE, DRIVING ON A LONG TRIP WITH THE CRUISE CONTROL ENABLED AND TRYING TO ACCELERATE UP A HILL AND SUDDENLY THE CAR WILL GO INTO AN ENGINE PROTECTION MODE AND REDUCE POWER TO THE EXTENT THAT I CAN'T ACCELERATE AND HAVE TO PULL OVER ON THE SIDE OF THE ROAD--(BOOST CONTROL MODULE HAS BEEN REPLACED AND THE ENGINE CONTROL MODULE HAS BEEN REPLACED.) AS LONG AS I DON'T USE THE CRUISE CONTROL THIS WILL NOT OCCUR. ALSO, THERE WAS A SOFTWARE UPDATE IN 2009. NEXT, AFTER TRYING TO ACCELERATE UP A HILL, THERE SEEMS TO BE INTERMITTENT REDUCTION IN ENGINE POWER, NOT ALLOWING THE CAR TO ACCELERATE. AFTER TRYING TO ACCELERATE THE "CHECK ENGINE" LIGHT HAS APPEARED AND WILL NOT GO OFF (WAITING TO HAVE THIS PROBLEM DIAGNOSED)... *TR

NHTSA ODI #10372343

35,000 miles · Dec 19, 2010
Power Train

2004 VOLVO XC 90 T6 TRANSMISSION. PURCHASED THIS VEHICLE NEW FROM DEALER. @ 35,000 THE TRANSMISSION FAILED. PRIOR TO THE FAILURE TRANSMISSION BEGAN TO SLIP AND THE VEHICLE WAS NON RESPONSIVE. DUE TO THE DELAY OF THE TRANSMISSION CATCHING AND PROPELLING THE VEHICLE FORWARD WE WERE IN A NEAR COLLISION WITH ANOTHER VEHICLE. UNIT WA…

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2004 VOLVO XC 90 T6 TRANSMISSION. PURCHASED THIS VEHICLE NEW FROM DEALER. @ 35,000 THE TRANSMISSION FAILED. PRIOR TO THE FAILURE TRANSMISSION BEGAN TO SLIP AND THE VEHICLE WAS NON RESPONSIVE. DUE TO THE DELAY OF THE TRANSMISSION CATCHING AND PROPELLING THE VEHICLE FORWARD WE WERE IN A NEAR COLLISION WITH ANOTHER VEHICLE. UNIT WAS REPLACED WITH A REFURBISHED ONE FROM THE DEALER. @ 85,000 THE VEHICLE BEGAN TO SHOW SYMPTOMS OF TRANSMISSION FAILURE AGAIN. THIS TIME IT WAS CORRECTED WITH A SOFTWARE UPDATE. NOW VEHICLE HAS 125,000 MILES AND TRANSMISSION FAILURE AGAIN. VEHICLE SHOWED NO SIGNS OF TRANSMISSION WEAR AND TEAR. JUST ALL OF THE SUDDEN VEHICLE CAME NON RESPONSIVE TO DRIVERS GAS INPUTS. THIS COULD BE A HUGE HAZARD IN HIGH TRAFFIC CONDITIONS AND POTENTIALLY RESULTING IN SERIOUS INJURIES AND EVEN DEATH. VOLVO REFUSES TO RECALL THIS UNITS. THEY ONLY OFFERED TO COVER 50% OF THE COST TO REPAIR. VOLVO KNOWS THAT THESE VEHICLES ARE PRONE TO PREMATURE TRANSMISSION FAILURE AND SHOULD RECALL AND REPLACE THIS UNITS AT NO COST TO THE CONSUMER. A QUICK INTER NET SEARCH AND YOU WILL FIND THOUSANDS OF PEOPLE LIKE ME EXPERIENCING TRANSMISSION PROBLEMS ON THESE VEHICLES. HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F18A651/ HTTP://WWW.MATTHEWSVOLVOSITE.COM/2009/03/TRANSMISSION-PROBLEMS/ HTTP://VOLVOFORUMS.COM/FORUM/SHOWTHREAD.PHP?T=7573&PAGE=2 SOMETHING NEEDS TO BE DONE BEFORE SOMEONE GETS HURT. *TR

NHTSA ODI #10371215

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.