The vehicle dossier US · 2004
2004 Volvo
XC90Problems & recalls
462 distinct owner reports in the NHTSA snapshot. Electrical system appears in 158 of them. Explore what was reported—and which official actions are on file.
01 / Owner-reported evidence
What owners reported.
Categories attached to 462 distinct reports. A report can mention more than one component, so category totals can overlap.
See original component labels
These are reports made to NHTSA, not verified diagnoses. More reports can reflect more vehicles, more time on the road, or greater reporting activity.
The reporting timeline
When reports arrived.
Reports by year filed, not by the year a problem occurred. Showing the latest 15 years with reports.
86,000 miles is the median among 410 reports with usable mileage. The middle half spans 64,500–116,000 miles.
This describes the submitted reports. It does not predict when a vehicle will fail.
02 / Official safety campaigns
6 recall campaigns on file.
A campaign can cover only certain production dates or configurations. The count does not tell you whether an individual car has an open recall.
EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)Campaign 10V566000
Reported concern
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Manufacturer’s stated response
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.
Manufacturer campaign: R231
Read campaign 10V566000 at NHTSAFUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMPCampaign 09V483000
Reported concern
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.
Manufacturer’s stated response
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.
Manufacturer campaign: R220
Read campaign 09V483000 at NHTSASTEERING:LINKAGES:TIE ROD ASSEMBLYCampaign 06V155000
Reported concern
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.
Manufacturer’s stated response
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.
Manufacturer campaign: R157
Read campaign 06V155000 at NHTSAVISIBILITY:WINDSHIELD WIPER/WASHERCampaign 06V144000
Reported concern
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.
Manufacturer’s stated response
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.
Manufacturer campaign: R156
Read campaign 06V144000 at NHTSAWHEELSCampaign 03V434000
Reported concern
ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.
Manufacturer’s stated response
DEALERS WILL REPLACE THE FRONT WHEEL SENSORS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
Manufacturer campaign: 127A
Read campaign 03V434000 at NHTSASEAT BELTS:REAR/OTHERCampaign 03V391000
Reported concern
ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.
Manufacturer’s stated response
DEALERS WILL INSPECT AND REPAIR THE SECOND AND/OR THIRD ROW SEAT BELT ATTACHMENTS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.
Manufacturer campaign: 127
Read campaign 03V391000 at NHTSA03 / The manufacturer’s record
Instructions. Updates. Responses.
222 distinct communications list this model-year. Showing the latest 12. A matching model-year does not establish that every engine, trim or reported symptom is covered.
35526.1.8This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required. NHTSA ID 11032678
This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.
Components: ENGINE. Confirm detailed applicability in the original document.
Source record 11032678 at NHTSA37809.1.1This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval…NHTSA ID 11032671
This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval. Current items under prior approval are listed in the "Service" section
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 11032671 at NHTSA19245This is a Technical Journal. Vehicle type and platform identification.NHTSA ID 11027173
This is a Technical Journal. Vehicle type and platform identification.
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 11027173 at NHTSA8501This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and…NHTSA ID 11020437
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. •Connect to the vehicle over a wired connection using a VOE (Volvo OBD to Ethernet) adapter and perform a NEW vehicle readout.
Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.
Source record 11020437 at NHTSAS10303Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there i…NHTSA ID 11016002
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing issue with the key fob. As a result, there is a possibility that the customer’s key fob is not paired to the vehicle. The corrective action is to download SP Software. S10303 affects 151 vehicles in the U.S and 5 in Canada.
Campaign / software reference: S10303
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 11016002 at NHTSAS10303Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there i…NHTSA ID 11015994
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing issue with the key fob. As a result, there is a possibility that the customer’s key fob is not paired to the vehicle. The corrective action is to download SP Software. S10303 affects 151 vehicles in the U.S and 5 in Canada.
Campaign / software reference: S10303
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 11015994 at NHTSA37175This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factoryNHTSA ID 11014113
This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 11014113 at NHTSA8501This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and…NHTSA ID 11014112
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. •Connect to the vehicle over a wired connection using a VOE (Volvo OBD to Ethernet) adapter and perform a NEW vehicle readout.
Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.
Source record 11014112 at NHTSATJ27536.21.1-2024-08-07Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery ServiceNHTSA ID 11007925
Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service
Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.
Source record 11007925 at NHTSA26745.13.14This is a Technical Journal: 12V Battery Testing MethodNHTSA ID 10249191
This is a Technical Journal: 12V Battery Testing Method
Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.
Source record 10249191 at NHTSAC00009COMPLIMENTARY UPGRADE C00009 DESCRIPTION.NHTSA ID 10241661
COMPLIMENTARY UPGRADE C00009 DESCRIPTION.
Components: ELECTRONIC STABILITY CONTROL (ESC):CONTROL MODULE:SOFTWARE · UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 10241661 at NHTSATJ3656330Rubber cushionNHTSA ID 10241651
Rubber cushion
Components: UNKNOWN OR OTHER. Confirm detailed applicability in the original document.
Source record 10241651 at NHTSARecords below contain the NHTSA bulk summary unless a document-reviewed explainer is linked. A service bulletin is not a safety recall or a promise of a free repair. Records may be revised or superseded; verify the current document with the manufacturer.
04 / Agency investigations
Official inquiries.
An investigation is an inquiry into a potential concern. Its presence does not establish a defect, and a closed case does not certify a car’s condition.
Central Electronic Module FailurePE10025
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.
Recorded closure: Nov 22, 2010
Find investigation PE10025FUEL PUMP LEAKPE09039
VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).
Recorded closure: Dec 22, 2009
Campaign reference in the source: 09V483000
Find investigation PE09039WINDSHIELD WIPER ARM PERFORMANCEPE05064
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.
Recorded closure: May 10, 2006
Campaign reference in the source: 06V144000
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