2005 VOLVO XC90 V8 - ENGINE NUMBER 6163 - COUNTER BALANCE SHAFT FAILURE DUE TO ENGINE DESIGN DEFECT. NO RECALL BY VOLVO DESPITE VERY HIGH VOLUME OF INCIDENTS AND THE SAFETY RISK TO DRIVERS AND PASSENGERS OF THEIR VEHICLES. NO CHECK ENGINE LIGHTS. VOLVO KNOWS ABOUT THIS ISSUE AND CHOOSES TO IGNORE IT, AUTHORITIES ARE A AWARE OF I…
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2005 VOLVO XC90 V8 - ENGINE NUMBER 6163 - COUNTER BALANCE SHAFT FAILURE DUE TO ENGINE DESIGN DEFECT. NO RECALL BY VOLVO DESPITE VERY HIGH VOLUME OF INCIDENTS AND THE SAFETY RISK TO DRIVERS AND PASSENGERS OF THEIR VEHICLES. NO CHECK ENGINE LIGHTS. VOLVO KNOWS ABOUT THIS ISSUE AND CHOOSES TO IGNORE IT, AUTHORITIES ARE A AWARE OF IT AND CHOSE NOT TO ENFORCE SAFETY STANDARDS ON VOLVO- "VOLVO FOR LIFE"...I THINK NOT.
NHTSA ODI #10544906
80,560 miles · Aug 26, 2013
Engine
I OWN A 2005 V8 XC90. LIKE SO MANY OTHERS I AM A RECENT MEMBER TO THE CB FAILURE CLUB. YEP. IT'S A CLUB. THE COUNTER BALANCE SHAFT FAILURE CLUB. THIS IS A DESIGN DEFECT THAT VOLVO IS AWARE OF AND DOES NOTHING TO REMEDY THE POOR SAPS WHO OWN A 2005 WITH THE FIRST 6883 ENGINES PRODUCED BY YAMAHA FOR VOLVO. AFTER 6883 VOLVO M…
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I OWN A 2005 V8 XC90. LIKE SO MANY OTHERS I AM A RECENT MEMBER TO THE CB FAILURE CLUB. YEP. IT'S A CLUB. THE COUNTER BALANCE SHAFT FAILURE CLUB. THIS IS A DESIGN DEFECT THAT VOLVO IS AWARE OF AND DOES NOTHING TO REMEDY THE POOR SAPS WHO OWN A 2005 WITH THE FIRST 6883 ENGINES PRODUCED BY YAMAHA FOR VOLVO. AFTER 6883 VOLVO MADE CHANGES TO THE DESIGN OF THE COUNTER BALANCE SHAFT, BY DRILLING A WEEP HOLE TO LET MOISTURE OUT. UNFORTUNATELY, MY ENGINE WAS IN THE 4000S. I LIVE IN SOUTHERN CALIFORNIA. ABOUT THE DRIEST CLIMATE YOU CAN GET, BUT YET RUST HAS DESTROYED MY COUNTER BALANCE AND THUS DESTROYED MY ENGINE WITH ONLY 80000 MILES ON IT.BTW, I HAVE HAD MY ENGINE SERVICED REGULARLY. BUT THE COUNTER BALANCE SHAFT IS SOMETHING THAT CAN NOT BE SERVICED WITHOUT TEARING THE ENGINE APART. IT LIES IN THE VALLEY OF THE V8. IN MY CASE, AND IN ALL THE OTHER CASES I AM READING ABOUT, THE BEARINGS RUSTED AND THE SHAFT RUSTED AND IT TORE APART MY ENGINE BLOCK. HAD I BEEN DRIVING ON A FREEWAY WITH MY CHILDREN AND LOST POWER IT COULD HAVE BEEN FATAL. HOW IS IT THAT THIS DESIGN FLAW WHICH CAUSES CATASTROPHIC ENGINE FAILURE CAN BE ALLOWED NOT TO BE RECALLED? IN FACT, THANKS TO A OVERCHARGED ALTERNATOR, I HAD JUST PUT A NEW $1400 COMPUTER IN THE CAR. YET, THE COMPUTER NEVER READ CHECK ENGINE. WHY? BECAUSE THE COMPUTER IS NOT MONITORING THE LUBRICATION IN A SEALED BEARING. AND IT IS IMPOSSIBLE WITHOUT TEARING THE ENGINE DOWN FOR 10 HOURS (1200.00 IN LABOR) TO GET TO THE COUNTER BALANCE SHAFT TO SEE THE CONDITION OF IT. PLEASE, FOR THE SAKE OF OTHERS WHO MIGHT BE UNFORTUNATE ENOUGH TO DRIVE THIS CAR AND FIND THEMSELVES ON A FREEWAY WHEN THE ENGINE BLOWS DUE TO CHEAP RUSTED BEARINGS -- ISSUE A RECALL!!! *TR
NHTSA ODI #10537349
107,000 miles · Apr 8, 2013
EngineExterior Lighting
I PURCHASED A 2005 VOLVO XC90 FOR $16,000. 6 MONTHS LATER THE ENGINE FREEZES UP. THAT COST $10,000.00 TO REPLACE THE ENGINE. LOOKED ON GOOGLE, VERY COMMON FOR THESE V8 ENGINES TO FREEZE UP. NOW THE HEADLIGHTS ARE ACTING UP. LOOKED ON GOOGLE AND FOUND THE HEADLIGHT ISSUE IS VERY COMMON. THIS WILL COST $3,000.00 TO REPAIR. THIS C…
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I PURCHASED A 2005 VOLVO XC90 FOR $16,000. 6 MONTHS LATER THE ENGINE FREEZES UP. THAT COST $10,000.00 TO REPLACE THE ENGINE. LOOKED ON GOOGLE, VERY COMMON FOR THESE V8 ENGINES TO FREEZE UP. NOW THE HEADLIGHTS ARE ACTING UP. LOOKED ON GOOGLE AND FOUND THE HEADLIGHT ISSUE IS VERY COMMON. THIS WILL COST $3,000.00 TO REPAIR. THIS CAR IS GOING TO COST ME ALMOST AS MUCH TO REPAIR IT AS I PAID FOR IT!! VOLVO IS LOOSING CONTROL. I WOULD LIKE YOU TO ISSUE A RECALL FOR THESE ENGINE ISSUES AND ISSUE A RECALL FOR THESE HEADLIGHT ISSUES. PLEASE GOOGLE 2005 VOLVO XC90 V8 ENGINE AND GOOGLE THE SAME YEAR AND MODEL ABOUT THE HEADLIGHT ISSUE. YOU WILL BE ASTOUNDED BY ALL THE PAGES OF COMPLAINTS ABOUT WHAT IS SUPPOSED TO BE A GREAT CAR. THESE CARS WHERE $62,000.00 BRAND NEW, WHAT A JOKE THEY CAN SELL THIS CAR WITH SO MANY PROBLEMS. PLEASE ISSUE A RECALL. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10505600
48,000 miles · Mar 13, 2013
Engine
COUNTER BALANCE SHAFT BEARING FAILURE AND COMPLETE DESTRUCTION OF ENGINE WHILE TRAVELING DOWN A CROWDED I-95 GOING INTO NY CITY WITH TWO CHILDREN IN CAR. THIS IS SUCH A COMMON PROBLEM WITH THE VEHICLE, THAT IT'S CRIMINAL TO NOT HOLD VOLVO ACCOUNTABLE TO FIX THIS. *TR
NHTSA ODI #10502696
97,000 miles · Feb 22, 2013
Engine
AT 97000 MILES THE COUNTERBALANCE SHAFT BROKE RESULTING IN ENGINE FAILURE. SERVICE AT VOLVO SAYS I NEED A NEW ENGINE. 7000-10000 FOR A USED ENGINE. CONTACTED MANUFACTURER, WAITING FOR RESPONSE. *TR
NHTSA ODI #10499664
115,000 miles · Dec 18, 2012
EnginePower TrainUnknown Or Other
VOLVO KNOWS THE V8 ENGINE ON THE 2005 XC90 IS FAULTY. SPECIFICALLY, THE COUNTERBALANCE SHAFT BEARING FAILING DUE TO WATER INTRUSION. FORTUNATELY MINE FAILED WHILE AT IDLE. UNFORTUNATELY THE ENTIRE ENGINE IS NOW SEIZED UP AND MY OTHERWISE CLEAN CAR IS A LARGE AND USELESS PAPERWEIGHT. IF THIS WERE TO HAPPEN WHILE THE CAR IS MO…
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VOLVO KNOWS THE V8 ENGINE ON THE 2005 XC90 IS FAULTY. SPECIFICALLY, THE COUNTERBALANCE SHAFT BEARING FAILING DUE TO WATER INTRUSION. FORTUNATELY MINE FAILED WHILE AT IDLE. UNFORTUNATELY THE ENTIRE ENGINE IS NOW SEIZED UP AND MY OTHERWISE CLEAN CAR IS A LARGE AND USELESS PAPERWEIGHT. IF THIS WERE TO HAPPEN WHILE THE CAR IS MOVING AT SPEED, IT COULD CAUSE A HORRIBLE ACCIDENT. UNLESS VOLVO ACTIVELY FINDS THE REMAINING ENGINES IN SERVICE AND FIXES THIS PROBLEM, IT REMAINS A RISK REGARDLESS OF THE MILEAGE. APPROPRIATELY, THEY SHOULD ALSO REIMBURSE ANYONE WHO WAS AFFECTED BY THIS PROBLEM SINCE THEY LEARNED OF IT BACK IN 2005. *TR
NHTSA ODI #10489205
81,500 miles · Oct 16, 2012
Engine
SUNDAY MORNING (10.14.12) CAR MAKING A HORRIBLE NOISE FROM ENGINE BLOCK. SOUNDS LIKE LOOSE BOLTS RATTLING AROUND INSIDE ENGINE BLOCK. CHECKED TRUSTED VOLVO FORUMS ON WEB. I HAVE HAD FOUR VOLVOS BETWEEN MYSELF AND MY WIFE: 2000 S40 (WIFE), 2001 S80 AND NOW 2005 S40 (WIFE) AND MY XC90 - USED THESE FORUMS TO STAY UP ON LATEST ISSUE…
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SUNDAY MORNING (10.14.12) CAR MAKING A HORRIBLE NOISE FROM ENGINE BLOCK. SOUNDS LIKE LOOSE BOLTS RATTLING AROUND INSIDE ENGINE BLOCK. CHECKED TRUSTED VOLVO FORUMS ON WEB. I HAVE HAD FOUR VOLVOS BETWEEN MYSELF AND MY WIFE: 2000 S40 (WIFE), 2001 S80 AND NOW 2005 S40 (WIFE) AND MY XC90 - USED THESE FORUMS TO STAY UP ON LATEST ISSUES/MAINTENANCE. THERE WERE SEVERAL POSTS WITH IDENTICAL ISSUE WITH THIS MODEL, YEAR AND V8 ENGINE. APPARENTLY, ONGOING ISSUE WITH COUNTER BALANCE SHAFT BEARING. DESIGN FLAW ALLOWS RUST TO OCCUR AT BEARING AND THEN THEN CB-SHAFT FAILS. WILL CAUSE INCREDIBLE DAMAGE TO ENGINE - MAYBE EVEN DEATH IF OCCURS AT HIGH SPEEDS. CALLED DEALER THIS MORNING, THEY ARE FAMILIAR WITH ISSUE, WANTED ME TO DRIVE IN OR TOW. COST IS PROHIBITIVE AND BASED ON LEGIONS OF SIMILAR CONSUMER REPORTS, AM ALREADY CERTAIN OF DIAGNOSIS. VOLVO NA EVEN DISTRIBUTED TECHNICAL BULLETIN TO SERVICE DEPTS TO DRILL MOISTURE RELIEF HOLE IN BEARING AREA AS FIX FOR THOSE UNDER WARRANTY!!! THAT'S INSANE!!! LINKS TO POSTS ABOUT ISSUE (ONE OWNER EVEN POSTED VIDEO OF HIS ENGINE NOISE): HTTP://FORUMS.SWEDESPEED.COM/SHOWTHREAD.PHP?123707-INTERMITTENT-CLATTERING-NOISE-FORM-HEAD-OF-BLOCK-WITH-ROUGH-RUNNING ALSO HTTP://S298.PHOTOBUCKET.COM/ALBUMS/MM262/DLRNORDIC/VEHICLE20PICTURES202010/ACTION=VIEW&CURRENT=IMG_0385.MP4 AND HTTP://WWWODI.NHTSA.DOT.GOV/COMPLAINTS/RESULTS.CFMODI_IDS=10313311&SEARCHTYPE=QUICKSEARCH&SUMMARY=TRUE&REFURL=EMAIL NEED VOLVO NA TO STEP UP AND HELP, HELP, HELP! HARDWORKING FAMILY MAN WITHOUT ESTIMATED 10-15K TO FIX THIS!!! ALSO, ISSUE WITH INTERNAL RAIN LEAKS ON 2005 S40 BUT NEVER RAISED FUSS. LOVE OUR VOLVOS BUT IN A REAL SPOT HERE. COME ON VOLVO NA, DO THE RIGHT THING!! WILL ACKNOWLEDGE VOLVO'S COMMITTMENT TO CONSUMER ALL ACROSS WEB!!! *TR
NHTSA ODI #10480745
88,000 miles · Aug 21, 2012
EngineExterior Lighting
TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE ENGINE STALLED WITHOUT ANY WARNING. THE VEHICLE FAILED TO RESTART AND WAS TOWED TO AN INDEPENDENT AUTO SHOP FOR DIAGNOSIS. THE TECHNICIAN STATED THE COUNTER BALANCE SHAFT BEARING WAS FROZEN AND THE ENGINE NEEDED TO BE REPLACED…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE ENGINE STALLED WITHOUT ANY WARNING. THE VEHICLE FAILED TO RESTART AND WAS TOWED TO AN INDEPENDENT AUTO SHOP FOR DIAGNOSIS. THE TECHNICIAN STATED THE COUNTER BALANCE SHAFT BEARING WAS FROZEN AND THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. IN ADDITION, THE HEADLIGHTS WOULD INTERMITTENTLY OPERATE AND HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 88,000. UPDATED 10/3/12 *CN UPDATED 10/09/2012 *JS
NHTSA ODI #10471742
64,983 miles · Jul 18, 2012
Engine
I NOTICED A GRINDING NOISE WHILE DRIVING AT NORMAL HIGHWAY SPEED AS IT GOT WORSE OVER THE NEXT DAY OR SO I BROUGHT IT TO MY LOCAL VOLVO SPECIALIST. AFTER SOME RESEARCH I WAS TOLD THAT THE PROBLEM WAS WITH THE BALANCE SHAFT AND WAS SPECIFIC TO THE 2005 XC90 V8. I CONTACTED VOLVO NORTH AMERICA AND RECEIVED NO COMPENSATION OR EVEN …
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I NOTICED A GRINDING NOISE WHILE DRIVING AT NORMAL HIGHWAY SPEED AS IT GOT WORSE OVER THE NEXT DAY OR SO I BROUGHT IT TO MY LOCAL VOLVO SPECIALIST. AFTER SOME RESEARCH I WAS TOLD THAT THE PROBLEM WAS WITH THE BALANCE SHAFT AND WAS SPECIFIC TO THE 2005 XC90 V8. I CONTACTED VOLVO NORTH AMERICA AND RECEIVED NO COMPENSATION OR EVEN SATISFACTORY CUSTOMER SERVICE. MY LOCAL VOLVO TECH RECOMMENDED I BRING THE CAR TO THE VOLVO DEALER, WHO WERE THE ONLY ONE'S AUTHORIZED TO DO THE REPAIR. THE ENGINE HEAD HAD TO BE REMOVED TO REPLACE THE BALANCE SHAFT AND THE BEARINGS NEEDED TO BE REASSEMBLED. IT'S AMAZING THAT THE SAME EXACT PROBLEM CAN BE REPORTED TO THIS EXTENT AND VOLVO STILL DOES NOTHING!! $4200 DOLLARS LATER, THE CAR WAS FIXED. I'M GLAD IT WAS CAUGHT PRIOR TO THE ENGINE NEEDED TO BE REPLACED.. *TR
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.
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.
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.
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.
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.
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
4
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.
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.
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.
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.
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