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
Fuel/propulsion System complaints
22 reportsADAS, AIR BAR Warning lights/urgent and High Gas fumes coming out from the rear seats when fully filled gas. We had called 800-458-1552 and guided us to plug in our VIN [XXX] on www.volvocars.com and nothing showed as far as recall and told us that these recalls expired and our 2005 Volvo are not eligible. 2005 Volvo XC90 that …
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ADAS, AIR BAR Warning lights/urgent and High Gas fumes coming out from the rear seats when fully filled gas. We had called 800-458-1552 and guided us to plug in our VIN [XXX] on www.volvocars.com and nothing showed as far as recall and told us that these recalls expired and our 2005 Volvo are not eligible. 2005 Volvo XC90 that relates to NHTSA Campaign Number: 09V483000, Make: VOLVO Model: XC90 Model Year: 2005 Manufacturer: VOLVO CARS OF N.A. LLC. Mfr's Report Date: DEC 17, 2009 NHTSA CAMPAIGN ID Number: 09V483000 NHTSA Action Number: PE09039 Component: FUEL SYSTEM, GASOLINEELIVERY:FUEL PUMP Potential Number of Units Affected: 136100 Summary: 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: 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 IS EXPECTED TO BEGIN DURING JANUARY 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552. My wife and I had purchased our Volvo XC90 in 2005, here in CA. Six months ago everytime we filled up the gas tank, we would smell a heavy fumes of gas as it was coming from the inside of the vehicle. We had called the Volvo 800 number above and guided us to plug in our VIN [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA
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 …
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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
BOUGHT CAR AND BEEN HAVING PROBLEMS EVERY SINCE I HAVE HAD PROBLEMS I KEEP FUEL INJECTION IN IT SO I CAN MOVE THE CAR TO POINT A AND B
GASTANK WAS LEAKING WHEN I WAS FILLING UP IN FULL TANK NOT VERY MUCH BUT I SMELL WHENEVER I WAS PARKING
TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT A FUEL LEAK WAS NOTICED UNDERNEATH THE VEHICLE. WHILE DRIVING APPROXIMATELY 57 MPH, THE VEHICLE SPUN OUT OF CONTROL AND ENDED UP ON THE SIDE OF THE ROAD. IN ADDITION, THE ANTI-SKID INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO VOLVO CARS BENTWOOD (314-644-9501, LO…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. THE CONTACT STATED THAT A FUEL LEAK WAS NOTICED UNDERNEATH THE VEHICLE. WHILE DRIVING APPROXIMATELY 57 MPH, THE VEHICLE SPUN OUT OF CONTROL AND ENDED UP ON THE SIDE OF THE ROAD. IN ADDITION, THE ANTI-SKID INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO VOLVO CARS BENTWOOD (314-644-9501, LOCATED AT 7700 MANCHESTER RD, ST. LOUIS, MO 63143) WHERE THE TRANSMISSION WAS REPLACED. THE FAILURE RECURRED AND THE VEHICLE WAS TAKEN BACK TO THE SAME DEALER. THE TECHNICIAN REPLACED THE FUEL CAP AND STATED THAT THE TRANSMISSION WOULD NOT BE REPLACED A SECOND TIME. THE MANUFACTURER WAS MADE AWARE OF THE FAILURES AND STATED THAT THE WARRANTY WAS EXPIRED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 122,000.
BEGAN SMELLING GAS ODOR AND NOTICED A SMALL LEAK. FOUND THAT THERE WAS A RECALL ON THE FUEL PUMP FOR MY MODEL AND YEAR BUT WHEN I CALL VOLVO ABOUT THE RECALL, MY VEHICLE WASN'T INCLUDED EVEN THOUGH MY VEHICLE WAS REGISTERED IN THE STATES WHERE THE RECALL WAS ASSOCIATED.
ALL THE VEHICLE LIGHTS WILL COME ON OVER THE DASH AND THE WHEEL LOCKS THEN IT SHUTS OFF WHILE I AM DRIVING. THIS IS SO UNSAFE FOR MY FAMILY. I AM NOT SURE WHY THERE IS NOT A RECALL FOR MY VIN # WHEN GOOGLE CLEARLY STATES THAT THIS IS A HAZARD AND THAT THERE ARE RECALLS FOR THIS PROBLEM.
THIS MODEL IS EXPERIENCING THE SAME AS RECALLS IN SIMILAR MODELS BUT FOR SOME REASON ISN'T RECALLED. FUEL SYSTEM IS FAULTY. LEAKING FUEL AND CRACKS IN FUEL PUMP. REPLACED WITH 4 PUMPS FROM VOLVO AND NOW IT IS KICKING OUT ECM CODE AND BLOWING EVERY FUEL SYSTEM INSTALLED.
TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE SLOWING DOWN OR BRAKING, THE VEHICLE SUDDENLY STALLED. IN ADDITION, THE CONTACT HAD TO MAKE SEVERAL ATTEMPTS TO GET THE VEHICLE TO START. THERE WAS AN ABNORMAL ODOR OF FUMES INSIDE AND OUTSIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN UNKNOWN DEALER WHO INDICATED THAT THE FUEL PUMP…
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TL* THE CONTACT OWNS A 2005 VOLVO XC90. WHILE SLOWING DOWN OR BRAKING, THE VEHICLE SUDDENLY STALLED. IN ADDITION, THE CONTACT HAD TO MAKE SEVERAL ATTEMPTS TO GET THE VEHICLE TO START. THERE WAS AN ABNORMAL ODOR OF FUMES INSIDE AND OUTSIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN UNKNOWN DEALER WHO INDICATED THAT THE FUEL PUMP ASSEMBLY NEEDED TO BE REPLACED. THE VEHICLE WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE MORE THAN TWO WEEKS AGO, BUT HAD NOT RESPONDED TO THE CONTACT WITH A SOLUTION. THE APPROXIMATE FAILURE MILEAGE WAS 95,000.
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.