Model year record

2004 Volvo XC90 recalls & problems

The 2004 Volvo XC90 has 6 safety recalls and 462 owner complaints on file with NHTSA. The most-reported problem area is electrical system (159 complaints).

Recalls6safety recalls

Complaints462filed by owners

Crashes · fires9 · 3reported in complaints

Injuries · deaths8 · 0reported in complaints

2004 Volvo XC90 in an NHTSA crash test — NHTSA crash test

Safety recalls

EquipmentNov 8, 2010

Electrical › Navigational system(global positioning system)

Recall 10V566000416 vehicles

Problem: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Fix: 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.

Fuel system, gasolineDec 18, 2009

Delivery › Fuel pump

Recall 09V483000158,733 vehiclesopened after NHTSA action (ODI)

Problem: 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.
Risk: 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.
Fix: 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.

SteeringMay 5, 2006

Linkages › Tie rod assembly

Recall 06V155000126,743 vehicles

Problem: 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.
Risk: THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.
Fix: 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.

VisibilityApr 28, 2006

Windshield wiper/washer

Recall 06V144000122,431 vehiclesopened after NHTSA action (ODI)

Problem: 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.
Risk: INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Fix: 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.

WheelsNov 4, 2003

Wheels

Recall 03V4340002,586 vehicles

Problem: ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.
Risk: THIS CAN ADVERSELY AFFECT A NUMBER OF VEHICLE FUNCTIONS, INCLUDING BRAKE, ENGINE, TRANSMISSION, AND TORQUE DISTRIBUTION CONTROL WHICH RELY ON THIS SIGNAL FOR PROPER OPERATION.
Fix: DEALERS WILL REPLACE THE FRONT WHEEL SENSORS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

Seat beltsOct 10, 2003

Rear/other

Recall 03V39100018,692 vehicles

Problem: ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.
Risk: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.
Fix: 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.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Volvo XC90 4-DR. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	★★★★★
Rollover risk	17.9%

2004 Volvo XC90 NHTSA side crash test — NHTSA side barrier crash test

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

XC90 FWD

19mpg combined

City / highway	16 / 22 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · Front-Wheel Drive · about $4,350/year to fuel

XC90 AWD

18mpg combined

City / highway	16 / 22 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,550/year to fuel

XC90 AWD

16mpg combined

City / highway	14 / 19 mpg
Fuel	Premium Gasoline

2.9 L · 6 cyl · Automatic (S4) · 4-Wheel or All-Wheel Drive · about $5,150/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Electrical systemIgnition; Wiring › Front underhood	159	3	2	1	94,250 mi
Power trainAutomatic transmission; Driveline	148	2	0	0	77,500 mi
Fuel system, gasolineDelivery › Fuel pump; Delivery › Hoses, lines/piping, and fittings	41	0	0	1	75,000 mi
Fuel/propulsion system	34	0	0	0	137,000 mi
Exterior lightingHeadlights	32	0	0	0	104,500 mi
Air bagsSide/window; Frontal	31	3	0	3	90,000 mi
Engine	28	0	0	0	104,789 mi
SuspensionRear; Front › Wheel bearing	26	0	0	0	58,439 mi
Engine and engine coolingEngine; Cooling system	24	0	0	0	76,375 mi
SteeringLinkages › Tie rod assembly; Steering wheel/handle bar	21	1	0	0	65,000 mi
Vehicle speed controlAccelerator pedal	17	1	0	0	113,026 mi
Unknown or other	15	0	0	0	101,000 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Electrical system
Instrument panel shuts down while driving on street. I believe it is the central electronic module that fails. It has happened numerous times and it is unsafe to drive without a speedometer, tachometer, odometer fuel gauge, and temperature gauge. It has now stopped altogether. Gauges just sit there and bounce
Mar 6, 2025
Fuel/propulsion system
Unsure of what the issue is with the vehicle but smells like gas in my garage and I found a recall I was never notified about I moved from Washington to Las Vegas and never received any info regarding the fuel pump recall as well as a noise thatâs been going on for a year now when I drive at 60 miles an hour Iâve had it looked at and no one seems to know what that issue is
Nov 8, 2024
Structure › Body
The rear right door cannot be open from inside the car. It opens fine from outside. I am aware there is a child safety lock, but in this case the problem is somewhere else. Regardless of the child safety lock position, the door cannot be open. This is a hazard, because in case oof an accident the passenger will e trapped inside the car.
Apr 7, 2023
Fuel/propulsion system
Few days ago I came home, parked the car inside the garage and went inside. An hour later I went to the garage for something and noticed a very strong gasoline odor coming from the car. It is not coming from the reservoir and I did not put any fuel recently, so it can't be explained with a fuel spill. I suspect it is coming from the fuel pump. I as hoping or it to goo away, but it did not. It has been a week already.
May 9, 2023
Electrical system
Unknown..but water accumulated under the passenger seat under the amp and electrical components after a storm or rainy day.and its a lot of water when I brake i can hear a water fall..and water rushing and moving along the bottom. Of the car as I am steering im worried that the wiring and electrical will be damaged by water exposure the battery always dies wires soaked and sitting in water underneath passenger and never can completely get the moisture smell out of front seat area..mildew..why is this water leaking or not draining correctly ??
Mar 10, 2023
Fuel system, gasoline
The contact owns a 2004 Volvo XC90. The contact stated that after refueling the vehicle, his wife noticed an abnormally strong gasoline odor. The contact's wife was able to continue driving the vehicle; however, the failure would return after refueling or on rainy days. The contact related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline) however, the VIN was not included. The dealer and the manufacturer were notified of the failure and informed the contact that they could not assist as the VIN was not under recall. The vehicle was not diagnosed or repaired. The failure mileage was approximately 30,000.
Nov 9, 2012 · 30,000 miles
Fuel system, gasoline
The contact owns a 2004 Volvo XC90. The contact stated that after his wife started the vehicle, she smelled the odor of gasoline. The contact had been advised by his wife that the vehicle was taking longer to start up and sometimes required two or three attempts to start the vehicle. The contact stated no warning light was illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic to be diagnosed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline). The failure mileage was approximately 212,000.
Sep 17, 2022 · 212,000 miles
Electrical system
On May 26, 2022, I was stuck in traffic for four hours, and the car's CEM (central electronic module) overheated causing the dashboard to shut down three times, meaning I lost all instrument readings. After each time the dashboard shut down, I had to pull over and reset fuse #27 to have the dashboard come back online temporarily. Because the CEM was already overheated due to its design flaw with improper ventilation, the dashboard would shut down again and again. A Google search would show this is a very common issue for 2004 Volvo models and before. Driving without any instrument readings is totally unsafe. I strongly urge you to force Volvo to issue a recall for 2004 and before models and…
May 26, 2022

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

Central Electronic Module FailureClosed
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…
PE10025 · opened Jul 20, 2010 · closed Nov 22, 2010
FUEL PUMP LEAKClosedLed to recall 09V483000
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…
PE09039 · opened Aug 31, 2009 · closed Dec 22, 2009
WINDSHIELD WIPER ARM PERFORMANCEClosedLed to recall 06V144000
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.
PE05064 · opened Dec 2, 2005 · closed May 10, 2006