2016 Volvo XC90

We are a repair facility and the vehicle arrived for a concern with a weak battery and a battery warning light. The battery was testing bad and was replaced but the other issues persisted. The vehicle was scanned for codes and the codes present in the computer were B139F11, P26DC00 & P059700. After researching these codes we discovered a technical service bulletin related to the same issue and codes (Ref. No: TJ 30268.6.0). The bulletin states "If any of above DTC´s are set in the ECM or CEM for the pre-heated thermostat in the cooling system, and/or if the customer complains of a charging system warning message in the Driver’s Information Module (DIM), follow advice under SERVICE". The bulletin then describes the required service "Replace the thermostat according to instructions in VIDA and erase DTC. Not replacing the thermostat can cause consequential damages". After reading this we followed the service in the bulletin and replaced the thermostat but the issue persist. At this point we have replaced multiple components in compliance with the service bulletin but the battery warning light is still displayed as well as auto start stop disabled & the A/C blower not operating correctly. The bulletin also states that if the issue persist to "submit a vehicle report using function group 2627" but it does not state where the report can be submitted.

The vehicle exhibits excessive oil consumption due to defective oil control rings, as highlighted by Quality Bulletin P10186. Additionally, the sunroof leaks, as noted in Technical Journal 31272 and TJ 35503.3.0, and there are further issues with the windshield wiper/turn signal system, the parking brake system, and the steering wheel module. Yes, the vehicle is available for inspection upon request. The excessive oil consumption and related engine issues can lead to engine damage and potential failure while driving, posing a serious safety risk. The sunroof leakage could impair visibility and cause electrical failures. The persistent dashboard warning messages and system malfunctions further distract and endanger the driver and others on the road. Yes, the problem has been reproduced and confirmed by various dealers and independent service centers, as indicated by numerous customer cases, court rulings, and a class-action lawsuit. Yes, the vehicle has been inspected by the manufacturer and documented in various technical journals and bulletins. There is no specific mention of inspection by police or insurance representatives. Yes, there were several warning lamps and messages, including the low oil light, Check Engine light, and messages related to the parking brake and windshield wiper/turn signal system. Symptoms such as slow acceleration, loss of power, higher tailpipe emissions, and a foul odor from the exhaust were also observed. These issues appeared shortly after acquiring the vehicle and persisted despite multiple repair attempts. The incident is primarily caused by engineering flaws and faulty materials, particularly the defective oil control rings leading to excessive oil consumption. Despite engine replacements, the problem persisted, indicating a fundamental design flaw. The sunroof leakage and other system malfunctions further suggest widespread safety and durability issues in the vehicle, rendering it unsafe to operate.

The contact owns a 2016 Volvo XC90. The contact stated that both oil and coolant would frequently be added to the engine as both the check engine and oil warning lights would appear on the instrument panel. The vehicle was taken to the dealer on multiple occasions where the crank shaft seal and fuel injectors were replaced; however, the failure persisted. One day while driving at 50 MPH, the vehicle began to hesitate upon depression of the accelerator pedal as the turtle warning light appeared on the instrument panel which indicated that there was reduced engine performance. The contact managed to drive the vehicle to Herb Chambers Volvo Cars of Norwood(1120 Providence Hwy #1, Norwood, MA 02062) where they were informed that contact that the fourth engine chamber had burned out which lead to engine failure. The manufacturer was notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 93,000.

The engine is burning oil due to a factory design defect in the piston ring design, as verified by Volvo through a technical bulletin. In the bulletin, Volvo states that there is a free oil consumption test available for up to 100k miles. However, once I brought the car in for the test, they denied doing it for free and did not send any notice by mail. Burning oil can lead to a fire risk and loss of power while driving on the highway, which can cause serious accidents. Their published bulletin confirms the issue. The car has not been inspected, and there are no warning lights.

This Volvo was bought in Worcester, Massachusetts. We used to live in USA before moving to our home country The Netherlands. Taking the Volvo with us. For many months the car consumes extreme amounts of oil. Indicating low oil every time. We need to refill every 1200-2000 km. We notified our Volvo dealer over and over again when having scheduled maintenance. No thorough inspection was done. We felt unsafe when traveling long distances, afraid the engine would break down or insecure about the oil consumption and what was causing it. We had an independent Volvo specialist inspect the car and he knew there is a design flaw in the cylinder pistons. The full problem was described by Volvo in technical journal [XXX]. Due to the fact that the Volvo dealer did not take the problem seriously, we had been driving with this problem way too long causing extreme cylinder defects resulting in having to replace the entire engine with a new one. We feel this matter should have been addressed better by Volvo and we request compensation for the costs made. We also don’t understand why Volvo didn’t recall this batch of cars that were designed with too small cylinder pistons for the capacity of the engine causing heavy oil consumption. We look forward to your reaction. As we live in The Netherlands, kindly e-mail. The Volvo importer of The Netherlands was also contacted, but they redirected us to you as the car was bought in the USA. We have a full repair report that can be shared upon request. Also the faulty engine is still with the Volvo specialist as proof of the described problems. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I have a 2016 XC90, been letting Volvo know of my oil consumption since Feb 2022 when I noticed more oil being used before changes were due! My vehicle failed the oil test performed on 12/6/23 at Volvo on Manchester in St Louis, and now this Volvo extended warranty won’t cover it. Why? Well, I never received anything from Volvo and wasn’t even aware until the service advisor told me to call. A “ticket” was put in with Volvo headquarters on 12/8/23 and they state that I’m out of the extended warranty, yet I NEVER had any opportunity to even get it since I didn’t receive anything! They want to replace where the current leak is, which is $2600, then do another test! This was my first actual oil consumption test! Despite bringing it to my advisor at the time, which I was well within these “extended warranty parameters” such as mileage, my advisor never suggested this test back in 2022. I was just informed in December 2023 there is a Volvo lawsuit regarding oil consumption. Apparently letters were sent out to Volvo customers of this “extended warranty” opportunity to fix the issue, which I never received anything! I was informed by the dealership to reach out to Volvo headquarters, which I have, a case was put in and 24 hours later I received an email stating they would NOT assist as I’m outside of those “warranty guidelines!.” Like I’ve advised them, how is an owner to know of this extended warranty if we weren’t notified!! it will be $2,600 to fix the current consumption THEN they want to do another consumption test to ensure it’s not leaking elsewhere!

Main Cooling system hose burst while driving down the road. Volvo Dealer said extremely rare for this to occur. Car overheated, all warning lights appeared and coolant exploded under hood all while driving.Had to have repaired $1000. Also a water leak inside 3rd row & leaks from rear view mirror area. Caused electrical damage to main system computer module, had to have replaced $2000+. All work done at volvo dealer. No frame damage,no missing parts, dealer stated unknown reason. Same thing is now happening a 2nd time and warranty will not cover water damage. Have spoken with others experiencing the same problem with roof leak. No alarms came on prior to combustion/main hose top engine area before break. Happend immediately, unexpectedly

The low coolant warning went off and the turn off engine notification came on. I turned off my vehicle and noticed all the coolant leaking out the bottom underneath the car. I had the vehicle towed to the nearest mechanic and I was given this diagnosis: Found cooling system low, pressure tested and located a slip line that runs from the coolant crossover tube to under the intake manifold. Coolant pipe runs from the crossover pipe down to the engine oil cooler. Volvo has an updated part number due to high failure rate of the component.

I own a 2016 XC90 that was regularly serviced by the Volvo dealer we bought the car from. My son and I were in my car on 08/02/2023 and we were at a stop light and something smelt a little off so my son put his window down to get fresh air. Then, we accelerated when the light turned green. Within 100 yds of accelerating my check engine light when on and simultaneously I lost acceleration. It was clear that something was wrong. I told my son we needed to unbuckle our seat belts and jump out of the car when I could get us safely stopped. We coasted into a parking lot where I found a safe spot to stop. While coasting I looked at my car screen to see if there was oil or other fluid that was low, but there was no indicator of a problem other than the check engine light that had just gone on at the same time as I lost the ability to accelerate. When the car stopped, I grabbed my purse next to me and before we were to the sidewalk the car was engulfed in smoke and then flames. Our lives were at risk within two minutes of the check engine light coming on. This car was on fire in a parking lot of a pediatricians office around other cars with young families inside. It was scary and extremely unsafe for my son and I and many other people who were around the vehicle. Our car received each recall replacement/fix that was identified. This was extremely scary and unsafe, it put our lives and others' lives at risk within 2 minutes. We along with many others called 911, the situation was immediately out of control.