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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
170,000 miles · Jan 15, 2016
Electrical SystemSteering

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING VARIOUS SPEEDS, THE POWER STEERING FAILED AND SEVERAL WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED. THE CONTACT STATED THAT A NEW ALTERNATOR WAS PLACED IN THE VEHICLE TWO DAYS PRIOR TO THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE …

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING VARIOUS SPEEDS, THE POWER STEERING FAILED AND SEVERAL WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED. THE CONTACT STATED THAT A NEW ALTERNATOR WAS PLACED IN THE VEHICLE TWO DAYS PRIOR TO THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 170,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10820417

101,000 miles · Nov 24, 2015
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHEN THE CONTACT ENTERED THE VEHICLE, THERE WAS AN ODOR OF FUEL INSIDE AND OUTSIDE THE VEHICLE. THE ODOR OF FUEL COULD BE SMELLED WHENEVER THE VEHICLE WAS DRIVEN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND IT WAS DISCOVERED THAT FUEL WAS LEAKING FROM THE VEHICLE, HOWEVER, THE FAI…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHEN THE CONTACT ENTERED THE VEHICLE, THERE WAS AN ODOR OF FUEL INSIDE AND OUTSIDE THE VEHICLE. THE ODOR OF FUEL COULD BE SMELLED WHENEVER THE VEHICLE WAS DRIVEN. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND IT WAS DISCOVERED THAT FUEL WAS LEAKING FROM THE VEHICLE, HOWEVER, THE FAILURE WAS UNABLE TO BE DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE DEALER WAS CONTACTED AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 101,000.

NHTSA ODI #10806469

133,000 miles · Nov 20, 2015
Electrical SystemVehicle Speed Control

THIS REPORT IS ABOUT A HAZARDOUS SITUATION WITH OUR 2004 XC90. THE ENGINE SHUT DOWN WITHOUT WARNING ON THE I5 FREEWAY! THE CAR SUDDENLY LOST POWER AND WE HAD TO COAST TO THE SIDE IN THE DARK. WE WERE LUCKY TO NOT GET HIT! THE DISPLAY SHOWED THE FOLLOWING ERROR CODE: ECM-981A. WE ARE AWARE OF THE FACT THAT THIS PROBLEM IS NOT NEW…

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THIS REPORT IS ABOUT A HAZARDOUS SITUATION WITH OUR 2004 XC90. THE ENGINE SHUT DOWN WITHOUT WARNING ON THE I5 FREEWAY! THE CAR SUDDENLY LOST POWER AND WE HAD TO COAST TO THE SIDE IN THE DARK. WE WERE LUCKY TO NOT GET HIT! THE DISPLAY SHOWED THE FOLLOWING ERROR CODE: ECM-981A. WE ARE AWARE OF THE FACT THAT THIS PROBLEM IS NOT NEW TO NHTSA AND THAT YOU HAVE RECEIVED SEVERAL REPORTS ON IT ALREADY. IT APPEARS THAT THE PROBLEM HAS TO DO WITH THE CRUISE CONTROL, AND EVER SINCE THE INCIDENT WE HAVE BEEN DRIVING THE CAR WITHOUT ENGAGING IT WITHOUT ANY PROBLEMS. THE MILEAGE ON THE CAR IS 138,000 MILES. THE PROBLEM OCCURRED WHEN ENGAGING THE CRUISE CONTROL ON AN UPHILL SLOPE. WE SPECULATE THAT IT MIGHT BE CAUSED BY ENGAGING THE CRUISE CONTROL AT THE SAME INSTANT AS THE CAR SHIFTS DOWN AUTOMATICALLY. I TALKED TO A VOLVO SERVICE TECHNICIAN WHO AID THAT HE HAD EXPERIENCED THE SAME PROBLEM WITH HIS OWN 2004 XC90 BUT HE WAS UNABLE TO FIND WHAT HAD CAUSED IT.

NHTSA ODI #10794989

140,000 miles · Oct 19, 2015
Fuel/propulsion System

LOOKING FOR REPAIRS ON FUEL ISSUES,I READ IMPORTANT INFORMATION ON WHAT I WAS LOOKING FOR. MY VOLVO HAD STARTED TO SMELL LIKE GAS, MORE IN THE REAR RIGHT SIDES OR BACK SIDE. I HAD READ THAT IT MAYBE OR IS A RECALL ISSUE . I BOUGHT MY VOLVO IN 4/28/15 BEING ONLY THE SECOND OWNER,I NOTICED THE SMELL CALLED THE DEALER WHERE I BOUG…

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LOOKING FOR REPAIRS ON FUEL ISSUES,I READ IMPORTANT INFORMATION ON WHAT I WAS LOOKING FOR. MY VOLVO HAD STARTED TO SMELL LIKE GAS, MORE IN THE REAR RIGHT SIDES OR BACK SIDE. I HAD READ THAT IT MAYBE OR IS A RECALL ISSUE . I BOUGHT MY VOLVO IN 4/28/15 BEING ONLY THE SECOND OWNER,I NOTICED THE SMELL CALLED THE DEALER WHERE I BOUGHT THE CAR, THEY SUGGESTED A DIAGNOSTIC CHECK. CAME UP AS POSSIBLE VOLVO RECALL, SINCE A BOUGHT THE CAR AS IS THEY DIDN'T FIX IT, THEY DID SUGGEST ON CALLING VOLVO DIRECT FOR THIS ISSUE. I MADE A APPOINTMENT WITH AUTONATION VOLVO IN SAN JOSE CA ON 6/15/2015. WHEN SHOWING UP FOR SERVICE THEY DENIED THAT MY CAR WAS NOT A RECALL ON THAT PARTICULAR PROBLEM FUEL ISSUES, IT WAS A RECALL ON 157. I WAS SURPRISED BECAUSE I HAD GONE FOR A FUEL ISSUE NOT A SUSPENSION ISSUE. SO MY FUEL ISSUE IS STILL PRESENT. SO ALL I CAN SAY IS THAT MY ISSUE WITH MY VOLVO IS A RECALL WITCH VOLVO OF SAN JOSE CA DON'T WANT TO FIX BECAUSE ITS NOT IN THE YEAR, MODEL, MAKE. CLEARLY I HAVE THE MOBIL MAKE AND YEAR, 2004 XC90 VOLVO DO TO ALL THE INFORMATION FOUND. MYSELF AND MY HUSBAND DRIVE THIS CAR EVERY DAY PLUS MY 7 YR. OLD WITH MY NEWBORN PASSENGERS BEING A HAZARD TO MY FAMILY.WE TOOK IN THE VOLVO IN ON SATURDAY THE 10/17 OF 2015 BECAUSE THE SMELL IS REALLY BAD, WE NEED TO DRIVE WITH THE AC AT ALL TIMES BECAUSE THE SMELL OUTSIDE IS SO BAD. WE GOT REJECTED AGAIN, SAYING THE SAME MY CAR DOES NOT FALL IN THAT RECALL ALSO DO TO MY VIN NUMBER NOT MATCHING WHO KNOWS WHAT, I NEED THIS FIXED BAD. WE HAVE ALSO HAD PEOPLE TELL US ABOUT THE SMELL BEING STRONG. AS YOU CAN SEE ITS A SAFETY AND FIRE HAZARD FOR MY FAMILY'S SAFETY, AND AT THIS TIME FINANCIAL HARDSHIP IS IN ISSUE DO TO MATERNITY LEAVE TO BE PAYING SOMETHING THAT CLEARLY ITS A VOLVO ISSUE , I THINK VOLVO SHOULD TAKE THIS AS A BIG CONCERN. I DO HOPE THIS PROBLEM GETS RESOLVED AND DONE. THANK YOU FOR YOUR TIME AND WORK. *TR

NHTSA ODI #10783188

135,000 miles · Oct 14, 2015
EnginePower Train

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING 65 MPH, THE ENGINE RPMS DECREASED AS IF THE BRAKE PEDAL WERE DEPRESSED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR REPAIRED AND THE FAILURE RECURRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT PROVIDED. THE FAILURE MILEAGE WAS 135,000....UPDATED 01/27/16 …

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING 65 MPH, THE ENGINE RPMS DECREASED AS IF THE BRAKE PEDAL WERE DEPRESSED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR REPAIRED AND THE FAILURE RECURRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT PROVIDED. THE FAILURE MILEAGE WAS 135,000....UPDATED 01/27/16 *BF *JS

NHTSA ODI #10782080

140,000 miles · Oct 11, 2015
Electrical SystemElectronic Stability Control (esc)

WHILE DRIVING AT ANY SPEED THE VEHICLES ELECTRICAL SYSTEM COMPLETELY SHUTS DOWN WITH OUT WARNING AS IF THE VEHICLE WAS OFF. THE ENGINE STAYS RUNNING WITH VERY MINIMAL POWER. THIS HAPPENED TO ME AT NIGHT WHILE DRIVING ON THE HIGHWAY, IT WAS RAINING AND ALL THE LIGHTS, WIPERS, EVERY ELECTRICAL PART JUST SHUT OFF, I AM LUCKY I DID …

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WHILE DRIVING AT ANY SPEED THE VEHICLES ELECTRICAL SYSTEM COMPLETELY SHUTS DOWN WITH OUT WARNING AS IF THE VEHICLE WAS OFF. THE ENGINE STAYS RUNNING WITH VERY MINIMAL POWER. THIS HAPPENED TO ME AT NIGHT WHILE DRIVING ON THE HIGHWAY, IT WAS RAINING AND ALL THE LIGHTS, WIPERS, EVERY ELECTRICAL PART JUST SHUT OFF, I AM LUCKY I DID NOT CRASH. AFTER RESEARCHING I THAT A LOT OF OWNERS HAVE THE SAME PROBLEMS AND THAT VOLVO IS AWARE OF THE DANGEROUS PROBLEM BUT DOES NOTHING ABOUT IT.

NHTSA ODI #10781357

113,000 miles · Oct 9, 2015
Electrical SystemPower TrainStructure

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE VEHICLE JERKED AND LOST POWER. THE CONTACT ALSO HEARD WATER RUNNING ON THE RIGHT PASSENGER SIDE DOOR AND UNDERNEATH THE DASHBOARD. THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAIL…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE VEHICLE JERKED AND LOST POWER. THE CONTACT ALSO HEARD WATER RUNNING ON THE RIGHT PASSENGER SIDE DOOR AND UNDERNEATH THE DASHBOARD. THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 113,00. THE VIN WAS NOT PROVIDED.

NHTSA ODI #10781038

104,000 miles · Oct 9, 2015
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO JERK AND THE INSTRUMENT PANEL FAILED. THE ACCELERATOR PEDAL WAS DEPRESSED AND FAILED TO RESPOND. THE VEHICLE WAS RESTARTED AND THE FAILURE RECURRED FREQUENTLY. THE CONTACT ALSO STATED THAT ON SEVERAL OCCASIONS IT TOOK SEVERAL ATTE…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO JERK AND THE INSTRUMENT PANEL FAILED. THE ACCELERATOR PEDAL WAS DEPRESSED AND FAILED TO RESPOND. THE VEHICLE WAS RESTARTED AND THE FAILURE RECURRED FREQUENTLY. THE CONTACT ALSO STATED THAT ON SEVERAL OCCASIONS IT TOOK SEVERAL ATTEMPTS TO START TO VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THE FAILURE WAS UNABLE TO BE DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 104,000.

NHTSA ODI #10780981

180,000 miles · Sep 30, 2015
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING AT 35 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. TH…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING AT 35 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 180,000. DJR

NHTSA ODI #10778762

117,000 miles · Sep 18, 2015
Electrical SystemEngine

EXITING DRIVEWAY IN REVERSE, UPON SWITCHING TO DRIVE THE DASHBOARD LIGHTS STARTED FLICKERING AND A JERK WAS FELT IN THE TRANSMISSION. SOON THE DASHBOARD GAUGES AND THE INDICATORS WENT DEAD. SEVERAL ERROR MESSAGES QUICKLY "SCROLLED" (BRAKE FAILURE, AIRBAG FAILURE, ABS FAILURE, ENGINE FAILURE) THEN THE CHECK ENGINE LIGHT CAME ON…

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EXITING DRIVEWAY IN REVERSE, UPON SWITCHING TO DRIVE THE DASHBOARD LIGHTS STARTED FLICKERING AND A JERK WAS FELT IN THE TRANSMISSION. SOON THE DASHBOARD GAUGES AND THE INDICATORS WENT DEAD. SEVERAL ERROR MESSAGES QUICKLY "SCROLLED" (BRAKE FAILURE, AIRBAG FAILURE, ABS FAILURE, ENGINE FAILURE) THEN THE CHECK ENGINE LIGHT CAME ON AND REMAINED ON. NO POWER TO DASHBOARD CONTROLS (GAUGES DEAD, NO LIGHTS/TURN SIGNALS, NO RADIO). FRONT WINDOWS WORK, BUT NOT REAR. VEHICLE DRIVES AS IF IN LOW GEAR. UNSAFE TO DRIVE SO HAD TOWED TO DEALER. THEY ARE RUNNING DIAGNOSTICS SO TBD ON SPECIFIC ISSUE AND COST TO REPAIR. CONCERNED AS NO RECALL AND SITUATION IS SO DANGEROUS (WHAT IF I'D BEEN ON FREEWAY!) VOLVO SHOULD RECALL ALL THE 2004 XC90 AS OTHERS REPORT SAME DEFECT

NHTSA ODI #10765020

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.