IllustrationI’ve had to change my fuel injection pump and catalytic convert twice on one year.
2005 Volvo XC90
Owner reports · Recalls · Investigations
More warning signs than most XC90 years
Owner complaints for the 2005 Volvo XC90 are substantially higher than the model-year median of 34.
About this comparison →How this year compares
Owner complaints by model year
Compare all XC90 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
140–25K
1325–50K
5350–75K
4375–100K
56100–150K
16150K+
195 reports with mileage · 28 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.
- Power Train. Review the 62 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 51 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. 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.
1 crash reports3 fire reports1 injury reports
Engine complaints
29 reportsWHEN CRANKING IT STALLS AND CUTS OFF AND AFTER DOING IT AROUND 10 TIMES IT FINALLY CRANKS THEN I HAVE TO HURRY TO PUT IN DRIVE TO GET THE MOTOR GOING IN ORDER TO KEEP HER CRUNK AND COUPLE WEEKS AGO BECAUSE THIS PROBLEM SHE STALLED OUT AND I HIT A HOLE IN THE ROAD AND BUSTED THE OIL PAN SO SHE HAS BEEN PARKED EVERY SINCE CAUSE …
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WHEN CRANKING IT STALLS AND CUTS OFF AND AFTER DOING IT AROUND 10 TIMES IT FINALLY CRANKS THEN I HAVE TO HURRY TO PUT IN DRIVE TO GET THE MOTOR GOING IN ORDER TO KEEP HER CRUNK AND COUPLE WEEKS AGO BECAUSE THIS PROBLEM SHE STALLED OUT AND I HIT A HOLE IN THE ROAD AND BUSTED THE OIL PAN SO SHE HAS BEEN PARKED EVERY SINCE CAUSE I HAD MY DAUGHTER IN THE CAR AND THAT WASN'T A PRETTY SIGHT SINCE THE HIT MADE HER NERVOUS NOW CAN'T GET HER TO GET IN THE CAR SO I NEED MY CAR FIXED AND I SEE IT HAS SEVERAL RECALLS AND ALL AND IT WAS ON A COUNTY STREET ONCE I GOT IT CRUNK BACK UP IT SMOKED BADLY TILL I TURNED IT OFF AND IT TOOK FOUR HOURS FOR ME TO GET IT OUT THE ROAD
THE KNOWN VOLVO BALANCE SHAFT FAILURE IN THE 05 XC90 V8 B8444S ENGINES SN UP TO 6833.VOLVO HAS KNOWN THE V8 ENGINE ON THE 2005 XC90 IS FAULTY SINCE 2005.SPECIFICALLY, THE COUNTERBALANCE SHAFT BEARING FAILING DUE TO WATER INTRUSION & HUMIDITY.MINE HAS NOT FAILED YET.I WILL BE LUCKY IF IT FAILS WHILE AT IDLE.BERGERON VOLVO IN META…
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THE KNOWN VOLVO BALANCE SHAFT FAILURE IN THE 05 XC90 V8 B8444S ENGINES SN UP TO 6833.VOLVO HAS KNOWN THE V8 ENGINE ON THE 2005 XC90 IS FAULTY SINCE 2005.SPECIFICALLY, THE COUNTERBALANCE SHAFT BEARING FAILING DUE TO WATER INTRUSION & HUMIDITY.MINE HAS NOT FAILED YET.I WILL BE LUCKY IF IT FAILS WHILE AT IDLE.BERGERON VOLVO IN METAIRIE, LA, SOLD ME A TICKING TIME BOMB TO DRIVE MY 4 YEAR OLD SON AROUND IN.THERE WAS NO DISCLOSURE OF THE KNOWN CB SHAFT BEARING FAILURE!I WOULD NOT HAVE PURCHASED THIS FOR ME & MY LITTLE BOY!MY ENTIRE ENGINE WILL EVENTUALLY SEIZE UP & MY OTHERWISE BEAUTIFUL CLEAN CAR WILL BE A LARGE & USELESS PAPERWEIGHT.IF THIS HAPPENS WHILE THE CAR IS MOVING AT SPEED,IT COULD CAUSE A HORRIBLE ACCIDENT!UNLESS VOLVO ACTIVELY (AND, I AM ONE OF THEM #1868) FINDS THE REMAINING AFFECTED ENGINES IN SERVICE & FIXES THIS PROBLEM, IT REMIANS A RISK REGARDLESS OF THE MILEAGE.MY CAR CURRENTLY HAS ONLY 72K MILES ON IT! I AM TRYING TO PREVENT THIS FORM HAPPENING, AND NEEDS TO BE PAID FOR BY VOLVO.THIS IS SOMETHING THAT IS IMPOSSIBLE FOR ME TO PREVENTATIVELY MAINTAIN! APPROPRIATELY,THEY SHOULD ALSO REIMBURSE ANYONE WHO WAS AFFECTED BY THIS PROBLEM SINCE THEY LEARNED ABOUT IT BACK IN 2005. THE BERGERONVOLVOCARS.COM SITE STATES MR. DENIS BERGERON HAS AN OPEN DOOR POLICY, WHEREBY CUSTOMERS CAN CONTACT HIM DIRECTLY,I EMAILED MR. BERGERON MY CONCERN LAST WEEK AND HAVE YET TO HEAR BACK FROM HIM. I WOULD LIKE A CALL BACK & SIT DOWN WITH MR. BERGERON TO HAVE THIS ENGINE DEFECT FIXED BEFORE I AM IN A HORRIBLE ACCIDENT OR LEFT WITHOUT A CAR.SOME WEBSITES FOR REFERENCE: HTTPS://WORKSHOP-MANUALS.COM/VOLVO/XC90_AWD/V8-4.4L_VIN_85_B8444S/ENGINE_COOLING_AND_EXHAUST/ENGINE/TIMING_COMPONENTS/BALANCE_SHAFT_BEARING/COMPONENT_INFORMATION/SERVICE_AND_REPAIR/ ; HTTPS://BLOG.FCPEURO.COM/THE-DARK-SIDE-OF-VOLVOS-EXCELLENT-V8 ; HTTPS://WWW.MATTHEWSVOLVOSITE.COM/FORUMS/VIEWTOPIC.PHP?F=10&T=87848
MY 2005 XC90 (ODOMETER APPROX. 178,000 MILES) THROWS CHECK ENGINE, REDUCED ENGINE PERFORMANCE AND ENGINE SERVICE REQUIRED DASHBOARD WARNINGS INTERMITTENTLY, DESPITE THE FACT THAT IT HAS A NEW CEM AND A SECOND NEW THROTTLE BODY IN LESS THAN TWO MONTHS. IT ALSO ISSUES A LOW BEAM HEADLIGHT BULB FAILURE WARNING, EVEN WHEN THE BULB I…
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MY 2005 XC90 (ODOMETER APPROX. 178,000 MILES) THROWS CHECK ENGINE, REDUCED ENGINE PERFORMANCE AND ENGINE SERVICE REQUIRED DASHBOARD WARNINGS INTERMITTENTLY, DESPITE THE FACT THAT IT HAS A NEW CEM AND A SECOND NEW THROTTLE BODY IN LESS THAN TWO MONTHS. IT ALSO ISSUES A LOW BEAM HEADLIGHT BULB FAILURE WARNING, EVEN WHEN THE BULB IS LIT, AND THE LEFT TURN BLINKER IS STICKY. SOMETIMES, THE DRIVER'S SEAT AND PASSENGER SIDE REAR VIEW MIRROR READJUST SIMULTANEOUSLY UPON OPENING THE DRIVER'S SIDE DOOR, WITH NO KEY IN THE IGNITION AND NO ONE SITTING IN THE SEAT. RECENTLY WHILE TRAVELING ON AN EXPRESSWAY AT 65 MPH, THE CAR ABRUPTLY LOST SPEED (A TERRIFYING EXPERIENCE) AND STRUGGLED TO ACCELERATE TO 40 MPH. A FEW DAYS LATER, IT LOST POWER IN HEAVY CITY RUSH-HOUR TRAFFIC (ALSO TERRIFYING) AS A RED LIGHT TURNED GREEN. IT BARELY MADE IT TO 10 MPH AND CAME CLOSE TO CAUSING A CHAIN REACTION CRASH WITH THE CARS BEHIND IT (ALSO TERRIFYING). LUCKILY I WAS ABLE TO STEER INTO A NEARBY BANK PARKING LOT, TURN IT OFF AND RESTART IT. IT DROVE NORMALLY BUT THE WARNING LIGHTS REMAINED. I HAVE TAKEN THE VEHICLE TO THE VOLVO DEALERSHIP MULTIPLE TIMES, CITING ELECTRICAL SYSTEM WOES, WHICH RESULTED IN THE TWO PREVIOUSLY MENTIONED REPAIRS. THEY IDENTIFIED A WIRING SHORT AS THE CAUSE BOTH TIMES, YET ACT MYSTIFIED AS TO WHY THE PROBLEMS HAVE PERSISTED DESPITE THOSE REPAIRS. I REPORTED THE SEAT/MIRROR SHIFTS AND THE ONGOING LOW BEAM BULB FAILURES TO THE SERVICE MANAGER, WHO REPLIED (WITHOUT EXAMINING THE CAR) THAT THE BULB WAS EITHER BURNT OUT OR LOOSE IN THE SOCKET, AND THAT THE SEAT SHIFTING WAS SIMPLY THE WAY THE MEMORY FUNCTION WORKS. I GET THE SENSE THAT VOLVO DOES KNOW WHAT'S WRONG WITH THIS VEHICLE, AND THEY DON'T WANT TO TELL ME. I AM EXTREMELY DISAPPOINTED AND FRUSTRATED WITH THE LACK OF ANSWERS, AND AM AFRAID TO DRIVE THIS CAR.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT THE VEHICLE RANDOMLY STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED AND PARKED ON THE CONTACT'S STREET DUE TO THE FAILURE. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS NOT AVAILABLE.
PLEASE REVIEW MY WRITE UP ABOUT THE COMPLAINT IN THE ATTACHED PDF DOCUMENT.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING 40 MPH, THE VEHICLE STALLED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO THE CONTACT'S HOME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WA…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING 40 MPH, THE VEHICLE STALLED. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO THE CONTACT'S HOME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, A FUEL ODOR EMITTED FROM THE REAR OF THE VEHICLE AS THE VEHICLE LOST POWER AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE CONTACT ALSO MENTIONED THAT FUEL WAS LEAKING FROM THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT AF…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, A FUEL ODOR EMITTED FROM THE REAR OF THE VEHICLE AS THE VEHICLE LOST POWER AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE CONTACT ALSO MENTIONED THAT FUEL WAS LEAKING FROM THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT AFTER THE VEHICLE WAS RESTARTED, THE FUEL ODOR RECURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL LINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 113,000.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED. IN ADDITION, THE VEHICLE JERKED AND STALLED WHILE DRIVING. THE VEHICLE WAS TAKEN TO A INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP INJECTOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFAC…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED. IN ADDITION, THE VEHICLE JERKED AND STALLED WHILE DRIVING. THE VEHICLE WAS TAKEN TO A INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP INJECTOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 98,000.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING APPROXIMATELY 45 MPH, THE VEHICLE EMITTED AN ABNORMAL NOISE AND STALLED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE WIRE CEM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING APPROXIMATELY 45 MPH, THE VEHICLE EMITTED AN ABNORMAL NOISE AND STALLED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE WIRE CEM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000.
Official recalls
610V566000 · 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.
07V221000 · Electrical SYSTEM:12V/24V/48V Battery:cables
May 25, 2007
ON CERTAIN PASSENGER VEHICLES, IT HAS BEEN DETERMINED THAT WHILE DOING BATTERY MAINTENANCE THE JACK'S CRANK HANDLE CAN BE MISPLACED UNDER A BRACKET WHICH RETAINS THE BATTERY.
Consequence & remedy
Consequence: MISPLACEMENT OF THE JACK'S CRANK HANDLE CAN POSE A SAFETY RISK AS IT CAN RESULT IN A SHORT CIRCUIT OF THE BATTERY WHICH COULD THEN LEAD TO A FIRE.
Remedy: DEALERS WILL INSPECT AND ENSURE PROPER PLACEMENT OF THE JACK CRANK HANDLE AND A WARNING LABEL WITH APPROVED TEXT WILL BE AFFIXED TO THE BRACKET WHICH RETAINS THE BATTERY. THIS WARNING LABEL WILL INFORM AN OPERATOR NOT TO PLACE THE JACK CRANK HANDLE BETWEEN THE BRACKET AND THE BATTERY FREE OF CHARGE. THE RECALL BEGAN ON JULY 7, 2007. 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.
05V529000 · Electrical System:starter Assembly:solenoid
Nov 17, 2005
ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, DUE TO AN ERROR IN THE FACTORY ASSEMBLY INSTRUCTION, THE B+TERMINAL MAY BE IN CONFLICT WITH THE STARTER MOTOR SOLENOID. IF THIS OCCURS, THE CONFLICT BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID MAY DEVELOP INTO A SHORT CIRCUIT OF THE BATTERY CABLE TO GROUND.
Consequence & remedy
Consequence: SMOKE MAY APPEAR FROM UNDER THE HOOD AND IT MAY BE IMPOSSIBLE TO START THE CAR. IF THE SHORT CIRCUIT HAPPENS DURING DRIVING, ELECTRICAL POWER COULD BE LOST RESULTING IN THE WARNING LAMPS BEING DEACTIVATED. AN ELECTRICAL SHORT COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT AND INCREASE DISTANCE BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID BY ADJUSTING THE TERMINAL. THE RECALL BEGAN ON JANUARY 31, 2006. OWNERS MAY 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
4PE10025 · 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.
EA06006 · Volvo XC90 Battery Cable Failures
Opened Mar 21, 2006 · Closed Jun 14, 2007
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery; Electrical SYSTEM:12V/24V/48V Battery:cables; Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Additional source detail variants (3)
Electrical SYSTEM:12V/24V/48V Battery:cables
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Electrical SYSTEM:12V/24V/48V Battery
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
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.
PE05057 · Volvo XC90 Battery Cable Failures
Opened Nov 2, 2005 · Closed Mar 23, 2006
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery:cables; Electrical System:starter Assembly; Electrical System:wiring; Electrical System:wiring:front Underhood
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Additional source detail variants (4)
Electrical SYSTEM:12V/24V/48V Battery:cables
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:starter Assembly
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:wiring:front Underhood
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:wiring
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.