IllustrationCOUNTER BALANCE SHAFT FAILURE LEADING TO COMPLETE ENGINE FAILURE. DEFECTIVE DESIGN. *TR
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 And Engine Cooling complaints
40 reportsTHE BALANCER BEARING AND SHAFT ON THE 2005 VOLVO XC90 SUV IS DEFECTIVE IN THE FIRST 6000 VEHICLES MANUFACTURED FOR THAT MODEL YEAR. THE BALANCER SHAFT BEARING CAN GO BAD AT ANY TIME WITHOUT WARNING, CAUSING CATASTROPHIC ENGINE DAMAGE. IF THIS HAPPENS ON A HIGHWAY WHILE TRAVELING AT A HIGH RATE OF SPEED, THE RESULTS COULD BE DEA…
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THE BALANCER BEARING AND SHAFT ON THE 2005 VOLVO XC90 SUV IS DEFECTIVE IN THE FIRST 6000 VEHICLES MANUFACTURED FOR THAT MODEL YEAR. THE BALANCER SHAFT BEARING CAN GO BAD AT ANY TIME WITHOUT WARNING, CAUSING CATASTROPHIC ENGINE DAMAGE. IF THIS HAPPENS ON A HIGHWAY WHILE TRAVELING AT A HIGH RATE OF SPEED, THE RESULTS COULD BE DEADLY. VOLVO NORTH AMERICA IS AWARE OF THIS AND DOES NOTHING TO ADDRESS THIS SERIOUS, POTENTIALLY DEADLY SITUATION. WE HAVE BEEN WORKING TO GET VOLVO OF NORTH AMERICA TO RECOGNIZE THIS ISSUE AND THEY HAVE DOING NOTHING TO DATE EXCEPT POINT TO MAINTENANCE, WHICH HAS NO IMPACT ON THE PROBLEM. THERE IS NO MAINTENANCE PROCEDURE TO INSURE THIS DOES NOT HAPPEN AND VOLVO WILL NOT PAY FOR DAMAGES. THE REMEDY IN MOST CASES IS AN ENGINE REPLACEMENT WHICH COSTS ABOUT $15,000 , AND AS MENTIONED, VOLVO WILL NOT PAY FOR IT. VOLVO MUST BE FORCED TO RECALL THESE VEHICLES AND FIX THE PROBLEM AND COMPENSATE OWNERS WHO HAVE BEEN IMPACTED. THESE VEHICLES MUST BE RECALLED AND THE PROBLEM MUST BE FIXED BEFORE COUNTLESS LIVES ARE PUT AT RISK BY THIS TICKING TIME BOMB THAT WILL GO OFF. AT 70 MILES AN HOUR , A FAILED ENGINE COULD LEAD TO DEATH. THERE ARE 6000 VOLVO XC90'S WITH THIS PROBLEM. *TR THE DEALER DIAGNOSED THE PROBLEM AS A COMPLETE ENGINE FAILURE DUE TO THE BALANCER BECOMING DAMAGED AND CAUSING CATASTROPHIC ENGINE FAILURE. THE CONSUMER WAS INFORMED IT WOULD COST $ 14,700 TO REPLACE THE ENGINE. UPDATED IVOQ 03/09/12
TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING APPROXIMATELY 25 MPH, THE CONTACT HEARD A LOUD NOISE EMITTING FROM THE FRONT END OF THE VEHICLE. IMMEDIATELY THERE WAS A SLIGHT LOSS OF ENGINE POWER DURING ACCELERATION. THE MALFUNCTION PROGRESSED AND THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO STATED THE ENGINE WOULD N…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE DRIVING APPROXIMATELY 25 MPH, THE CONTACT HEARD A LOUD NOISE EMITTING FROM THE FRONT END OF THE VEHICLE. IMMEDIATELY THERE WAS A SLIGHT LOSS OF ENGINE POWER DURING ACCELERATION. THE MALFUNCTION PROGRESSED AND THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO STATED THE ENGINE WOULD NEED TO BE REPLACED AS A RESULT TO THE ENGINE BALANCE SHAFT FRACTURING. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.
HEARD LOUD TICKING NOISE COMING FROM ENGINE AT 86330K MILES. VEHICLE RIDE BECAME SOMEWHAT ROUGH. DIAGNOSED AT VOLVO DEALERSHIP AS BALANCE SHAFT BEARING "PART FAILURE". EST. TO FIX: ~$3800. VOLVO AGREED TO COMPENSATE FOR THE PARTS, APPROX $1500. BALANCE OF $2325.50 PAID BY VEHICLE OWNER. TOOK 1 WEEK FOR VOLVO TO OBTAIN PARTS AS…
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HEARD LOUD TICKING NOISE COMING FROM ENGINE AT 86330K MILES. VEHICLE RIDE BECAME SOMEWHAT ROUGH. DIAGNOSED AT VOLVO DEALERSHIP AS BALANCE SHAFT BEARING "PART FAILURE". EST. TO FIX: ~$3800. VOLVO AGREED TO COMPENSATE FOR THE PARTS, APPROX $1500. BALANCE OF $2325.50 PAID BY VEHICLE OWNER. TOOK 1 WEEK FOR VOLVO TO OBTAIN PARTS AS THEY ARE NOT COMMONLY STOCKED OR WERE BACK ORDERED. ON LINE RESEARCH REVEALED THIS TO HAVE BEEN A PROBLEM WITH EARLY 2005 XC90 V8'S. WATER/CONDENSATION/VAPOR IS ABLE TO GET IN AND RUST THE BEARING LEADING TO ENGINE FAILURE. A TSB WAS ISSUED (? WHEN) FOR A FIX TO DRILL A "WEEPING HOLE" IN ENGINE BLOCK TO DRAIN WATER FROM THE BEARING. *TT
PURCHASED USED 2005 VOLVO XC90 IN SPRING OF 2010. DURING THE NEXT YEAR EXPERIENCED VERY INTERMITTENT ELECTRICAL ISSUES. EXAMPLES ARE LOCKS NOT WORKING, BLINKER, RADIO. THESE ISSUES LITERALLY ONLY HAPPENED A COUPLE TIMES. IN APRIL 2011 HAD BIYEARLY SAFETY AND EMISSIONS DONE AT LOCAL DEALERSHIP (NON VOLVO) AND IT DID NOT PASS EM…
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PURCHASED USED 2005 VOLVO XC90 IN SPRING OF 2010. DURING THE NEXT YEAR EXPERIENCED VERY INTERMITTENT ELECTRICAL ISSUES. EXAMPLES ARE LOCKS NOT WORKING, BLINKER, RADIO. THESE ISSUES LITERALLY ONLY HAPPENED A COUPLE TIMES. IN APRIL 2011 HAD BIYEARLY SAFETY AND EMISSIONS DONE AT LOCAL DEALERSHIP (NON VOLVO) AND IT DID NOT PASS EMISSIONS. NEXT DAY TOOK MY VOLVO XC90 TO WEISS VOLVO AND IT PASSED EMISSIONS (WITHOUT ME KNOWING THEY CLEARED ERRORS ON THE CAR TO GET IT TO PASS. THIS MUST BE THE REASON IN EUROPE THAT DEALERSHIPS CAN'T INSPECT THEIR OWN MAKE OF CARS) ON JULY 17 2011 I WAS DRIVING DOWN THE HIGHWAY WITH MY 1 YEAR OLD IN THE BACK SEAT. RADIO WENT OUT. A FEW MINUTES LATER ALMOST EVERYTHING IN THE CAR SHUT DOWN EXCEPT FOR THE ENGINE. LOST A/C (IT WAS 110 THAT DAY), LOST POWER STEERING, BRAKING WAS INTERMITTENT, NO BLINKERS, NO HEADLIGHTS, NO LIGHTS IN INTERIOR, WHILE I WAS AT FULL SPEED ON THE HIGHWAY. I AM NOT SURE IF ENGINE WAS INTERMITTENT OR NOT BECAUSE I GOT OFF AS SOON AS I COULD. I WAS VERY CLOSE TO WEISS VOLVO SO DROPPED IT OFF THERE AGAIN ON THE DATE OF THE TOTAL FAILURE. CALLED VOLVO CUSTOMER CARE ON JULY 18 2011 TO FILE COMPLAINT. WEISS VOLVO CALLED BACK AND TOLD US CAR WOULDN'T START. CALLED BACK LATER IN THE DAY AND SAID THEY SAW THAT EVERYTHING WENT OUT AND CAR WAS FULL OF CODES. WEISS SENT IN AN ESTIMATE FOR $1500 TO REPLACE ECM. I ASKED WEISS TO PERFORM AN EMISSIONS TEST (BY MO LAW MANUFACTURER'S CARS MUST PASS EMISSIONS TEST UP TO 80K MILES AND MY CAR HAD 61K) I RESEARCHED ECM AND FOUND VERY SIMILAR STORIES TO MINE AND BROUGHT THIS UP TO VOLVO NA. VOLVO NA TOLD WEISS VOLVO TO "RESET" MY CAR (AGAIN WITHOUT MY PERMISSION). THE CAR THEN WAS FUNCTIONAL AFTER RESET. WEISS THEN "TESTED" MY CAR FOR ALMOST 3 WEEKS TO FIGURE OUT THE DESIGN FLAW FOR A TOTAL OF 451 MILES. THE MECHANIC TOLD ME IT WAS THE ECM BUT VOLVO NA SAID IT WAS VARIOUS OTHER REASONS AND WOULDN'T REPLACE IT. CAR STILL BROKE. REACHED LIMIT. *KB
1.JULY 8, 2011. 2005 VOLVO XC90 BALANCE SHAFT BROKE OFF WITHIN CAR ENGINE. HEARD A LOUD SOUND COMING FROM CAR ENGINE, AND LOST A GREAT DEAL OF POWER WHILE DRIVING ON HIGHWAY. 2.FURTHER DAMAGE TO THE VEHICLE ENGINE COULD HAVE BEEN DONE DUE TO ACCELERATING TO GET OF THE HIGHWAY IN ORDER TO AVOID A COLLISION FROM VEHICLES COM…
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1.JULY 8, 2011. 2005 VOLVO XC90 BALANCE SHAFT BROKE OFF WITHIN CAR ENGINE. HEARD A LOUD SOUND COMING FROM CAR ENGINE, AND LOST A GREAT DEAL OF POWER WHILE DRIVING ON HIGHWAY. 2.FURTHER DAMAGE TO THE VEHICLE ENGINE COULD HAVE BEEN DONE DUE TO ACCELERATING TO GET OF THE HIGHWAY IN ORDER TO AVOID A COLLISION FROM VEHICLES COMING FROM BEHIND. THIS WAS A SCARY LIFE AND DANGEROUS EXPERIENCE. 3.VOLVO HAVING EXPLAINED WHAT CREATED THE PROBLEM TO DATE. THE ENGINE WILL HAVE TO BE PULLED OUT AND ALMOST RE-BUILT AT A COST TO ALMOST $8500.00 EXTENDED WARRANTY I PAID $4,100 FOR IS NOT COVERING FULL COST. I AM RESPONSIBLE FOR OVER $2000 + COST OF CAR RENTALS TO DATE. JULY 28, 2011, CAR IS STILL WITH VOLVO. *TR
1. HEARD MARBLE NOISES UNDERHOOD AFTER 56,000 MILES OF NORMAL DRIVING. WELL MAINTAINED. 2. BALANCE SHAFT BEARING BROKE APART AND PUT OUT METAL SHARDS BETWEEN CYLINDER HEADS. LOUD METALLIC NOISE FROM ENGINE. VEHICLE WAS SHUT DOWN IMMEDIATELY AFTER PULLING OVER TO AVOID ENGINE DESTRUCTION AND TRAFFIC ACCIDENT DUE TO HALTED VE…
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1. HEARD MARBLE NOISES UNDERHOOD AFTER 56,000 MILES OF NORMAL DRIVING. WELL MAINTAINED. 2. BALANCE SHAFT BEARING BROKE APART AND PUT OUT METAL SHARDS BETWEEN CYLINDER HEADS. LOUD METALLIC NOISE FROM ENGINE. VEHICLE WAS SHUT DOWN IMMEDIATELY AFTER PULLING OVER TO AVOID ENGINE DESTRUCTION AND TRAFFIC ACCIDENT DUE TO HALTED VEHICLE. HAD TO BE TOWED. 3. BALANCE SHAFT BEARING IS BEING REPLACED. OLD PART (IN PIECES) AVAILABLE FOR ANALYSIS. *TR
I HAVE A 2005 VOLVO XC90 V8 THE CAR HAS BEEN DEVELOPING A SHAKE, I BROUGHT IT TO VOLVO FOR A CHECK UP, NOTHING WAS REPORTED AS UNUSUAL. YESTERDAY I HEARD KNOCKING IN THE ENGINE AND IMMEDIATELY FLATBEDDED IT TO THE DEALERSHIP, THE WENT TO DIAGNOSE AND THE ENGINE HAS FROZE. THE DEALER IS RESEARCHING AND EXPLAINED IT IS OUT OF WA…
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I HAVE A 2005 VOLVO XC90 V8 THE CAR HAS BEEN DEVELOPING A SHAKE, I BROUGHT IT TO VOLVO FOR A CHECK UP, NOTHING WAS REPORTED AS UNUSUAL. YESTERDAY I HEARD KNOCKING IN THE ENGINE AND IMMEDIATELY FLATBEDDED IT TO THE DEALERSHIP, THE WENT TO DIAGNOSE AND THE ENGINE HAS FROZE. THE DEALER IS RESEARCHING AND EXPLAINED IT IS OUT OF WARRANTY WITH A NEW ENGINE COSTING $14,000.00, READING OTHER BULLETINS I SUSPECT THIS IS A COUNTERBALANCE SHAFT BEARING FAILURE AND IS OCCURRING WITH ALL 2005 V8 XC90'S AS THEY INCREASE IN AGE AND EXIT ANY WARRANTY PERIOD. I HOPE SOMEONE CAN DO SOMETHING, A NEW ENGINE COST AS MUCH AS IT'S TRADE-IN VALUE. SUCH A KNOW ISSUE SHOULD BE INVESTIGATED WITH VOLVO PICKING UP THE COST. *TR
TL*THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED WHILE DRIVING 30 MPH THE VEHICLE SHUT OFF WITHOUT WARNING. THE CONTACT HAD THE VEHICLE TOWED TO A LOCAL MECHANIC. THE MECHANIC NOTICE THE TIMING CHAIN BROKE CAUSING THE ENGINE TO LOCK UP. THE MECHANIC STATED THE ENGINE NEEDS TO REPLACED. THE MECHANIC REPLACED THE ENGINE.…
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TL*THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED WHILE DRIVING 30 MPH THE VEHICLE SHUT OFF WITHOUT WARNING. THE CONTACT HAD THE VEHICLE TOWED TO A LOCAL MECHANIC. THE MECHANIC NOTICE THE TIMING CHAIN BROKE CAUSING THE ENGINE TO LOCK UP. THE MECHANIC STATED THE ENGINE NEEDS TO REPLACED. THE MECHANIC REPLACED THE ENGINE. THE CONTACT NOTICE NUMEROUS COMPLAINT REGARDING ENGINE MALFUNCTIONS FOR THIS YEAR MAKE AND MODEL. THE CONTACT CALLED THE MANUFACTURER AND THE MANUFACTURER STATED SINCE THE VEHICLE HAS NOT BEEN SERVICED AT A DEALER THEY ARE NOT RESPONSIBLE FOR THE REPAIRS. THE CONTACT STATED IF THE VEHICLE WAS ON THE HIGHWAY AND THE ENGINE FAILED A CRASH COULD HAVE OCCURRED. THE FAILURE MILEAGE WAS 75,000.
2005 XC90 V8. POWER REDUCTION, ENGINE NOISE, ENGINE FAILURE DUE TO DEFECTIVE REAR COUNTER BALANCE SHAFT BEARING. FAILURE AT 35,000 MILES ON ENGINE, 4 YR OLD, DEALER SERVICED. LONG BLOCK REPLACED WHILE UNDER EXTENDED 7-YR WARRANTY. BY DEALER. TOTAL REPAIR COST (W/O WARRANTY) WOULD HAVE BEEN $15,000. *TR
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.