Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

CarComplaints.com Notes: The XC90 took its “freshman 15” of transmission complaints and turned it into a “sophomore 45.” The 2004 XC90 saw 3X as many complaints about the transmission failing as it did in its inaugural North American model year! By the following year, transmission complaints fell back in line with the 2003. That sharp spike in complaints means we recommend avoiding the 2004.

On top of transmission complaints, the 2004 XC90 also has problems with a sudden loss of power. The lucky ones are met with a “reduced engine performance” message, while others are left stranded on the side of the road waiting for a tow.

1.4

hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
118,055 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Volvo XC90 fuel system problems

fuel system problem

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2004 Volvo XC90 Owner Comments (Page 1 of 2)

problem #21

Sep 212016

XC90

  • 114,000 miles

A D V E R T I S E M E N T S

There is a very strong smell of gas while driving at all speeds. The smell gets worse on the right hand rear passenger seat when parked. I took it in for diagnosis and was told there is a leak on top of the fuel pump. I called to Volvo of North America see if there is a recall. The lady I talked to was very nice and seamed knew exactly what I was talking about. If this a problem why is there no recall in all states in usa.

- Madison, WI, USA

problem #20

Apr 012016

XC90

  • miles
On the right rear side a smell of gas is present when I'm out side the car the I can smell it more

- Fairhaven, MA, USA

problem #19

Apr 152016

XC90

  • miles
There has been problems with steering the driver shafts the fuel pump airbags and wheels making a clicking noise while driving on highway. The gas smell is always inside the car and mechanic has said it's from the fuel pump defect during manufacturer. Along with the other fore-mention defects.Volvo does not want to address issues because age of car. There is a defective sunroof that allows water to leak inside the car during rain fall. There has been a top class action placed against Volvo for this. They wanted to charge me $700 to $800 for this defect and $1200 to $1500 for fuel pump.

- Trenton, NJ, USA

problem #18

Mar 012016

XC90

  • 140,000 miles

A D V E R T I S E M E N T S

Fuel leak and smell passenger rear vehicle

- Lemont, IL, USA

problem #17

Feb 272016

XC90

  • 75,000 miles
The contact owns a 2004 Volvo XC90. While parked, there was a strong odor of fuel coming from the vehicle. The smell worsened while driving. The contact took the vehicle to a local mechanic who diagnosed that the fuel pump needed to be repaired. The repairs were not performed. The manufacturer was not made aware of the failure. The VIN was unknown. The failure mileage was approximately 75,000.

- St Louis, MO, USA

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problem #16

Jan 302016

XC90

  • 69,000 miles
The contact owns a 2004 Volvo XC90. The contact stated that after the vehicle was parked, there was a fuel odor emitting inside the rear of the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure and the VIN was not included in NHTSA campaign number: 09V483000 (fuel system, gasoline). The failure mileage was 69,000.

- Broadway, NJ, USA

problem #15

Oct 012015

XC90

  • 101,000 miles

A D V E R T I S E M E N T S

The contact owns a 2004 Volvo XC90. When the contact entered the vehicle, there was an odor of fuel inside and outside the vehicle. The odor of fuel could be smelled whenever the vehicle was driven. The vehicle was taken to an independent mechanic and it was discovered that fuel was leaking from the vehicle, however, the failure was unable to be determined. The vehicle was not repaired. The dealer was contacted and informed the contact that the VIN was not included in NHTSA campaign number: 09V483000 (fuel system, gasoline). The manufacturer was not made aware of the failure. The approximate failure mileage was 101,000.

- Fort Thomas, KY, USA

problem #14

Jun 152015

XC90 5-cyl

  • 140,000 miles
Looking for repairs on fuel issues, I read important information on what I was looking for. My Volvo had started to smell like gas, more in the rear right sides or back side. I had read that it maybe or is a recall issue. I bought my Volvo in 4/28/15 being only the second owner, I noticed the smell called the dealer where I bought the car, they suggested a diagnostic check. Came up as possible Volvo recall, since a bought the car as is they didn't fix it, they did suggest on calling Volvo direct for this issue. I made a appointment with autonation Volvo in san jose ca on 6/15/2015. When showing up for service they denied that my car was not a recall on that particular problem fuel issues, it was a recall on 157. I was surprised because I had gone for a fuel issue not a suspension issue. So my fuel issue is still present. So all I can say is that my issue with my Volvo is a recall witch Volvo of san jose ca don't want to fix because its not in the year, model, make. Clearly I have the mobil make and year, 2004 XC90 Volvo do to all the information found. Myself and my husband drive this car every day plus my 7 yr. Old with my newborn passengers being a hazard to my family.we took in the Volvo in on Saturday the 10/17 of 2015 because the smell is really bad, we need to drive with the ac at all times because the smell outside is so bad. We got rejected again, saying the same my car does not fall in that recall also do to my VIN number not matching who knows what, I need this fixed bad. We have also had people tell us about the smell being strong. As you can see its a safety and fire hazard for my family's safety, and at this time financial hardship is in issue do to maternity leave to be paying something that clearly its a Volvo issue, I think Volvo should take this as a big concern. I do hope this problem gets resolved and done. Thank you for your time and work.

- San Jose, CA, USA

problem #13

Jan 012015

XC90

  • miles
The contact owns a 2004 Volvo XC90. While in park, the contact heard a noise. All the warning lights on the instrument panel failed to illuminate and the vehicle stalled. In addition, the contact stated that the odometer displayed an incorrect reading and there was a fuel odor in the vehicle. The contact was unable to restart the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the battery needed to be replaced. The vehicle was repaired; however, the failure recurred on numerous occasions. The vehicle was towed back to the independent mechanic who was unable to diagnose or repair the vehicle. The vehicle was taken to another independent mechanic who diagnosed that the central electronic module and the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.

- Hoffman Estates, IL, USA

problem #12

May 012015

XC90

  • 215,000 miles
The contact owns a 2004 Volvo XC90. While the vehicle was parked, an extremely strong odor of fuel emitted near the fuel tank on the rear passenger side. The fuel tank exhibited fuel leakage, but there was no fuel visible on the ground. The contact experienced the same failure as mentioned in NHTSA campaign number: 09V483000 (fuel system, gasoline); however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the issue. The approximate failure mileage was 215,000.

- Miami Lakes, FL, USA

problem #11

Apr 132015

XC90

  • 143,000 miles

A D V E R T I S E M E N T S

My 2004 Volvo XC90 with a 2.5T engine, 7 pass, intermittently and inadvertently stalls while driving it. It is scary because all electrical goes off, instrument panel, radio, lights, etc, several warning messages appears, such ABS, air bags failure, brake failure, engine failure, etc. It won't respond to acceleration and brakes are very hard to push, the engine does not stop. I have to stop, turn it off, wait few minutes, then start it, everything comes to normal again but with the check engine and the air bags message, then after some minutes of driving the same stalling and electrical issues happen again. This is serious because you are on freeway and you loose brakes and engine control, no information in instrument panel, etc. I found that the relays in the cem (control electronics module) are super hot possibly due to loose connections, in the video below you will see the problems and infrared pictures of the cem. Please help!!!!!! please help!!!!!! please help!!!!!! please help!!!!!! please see my youtube video and other videos with the same issue search for XC90 issues, XC90 stalling, XC90 electrical problems, etc. Https://www.youtube.com/watch?V=fwulb1sksie&feature=youtu.be thank you

- Raleigh, NC, USA

problem #10

Mar 152015

XC90

  • 126,000 miles
To whom it may concern: I currently own a 2004 XC90 T6, and have now encountered the same issue twice with my vehicle. Last year around the same time frame, there was a terrible scent of gasoline fumes throughout the cabin and exterior of the vehicle. The strongest concentration of the odor occurred around the backseat, passenger side. I took the vehicle to my mechanic and it was conclude that the was a fume leak occurring from the seal around the fuel pump. I purchased a new pump and seal from Volvo and had the unit replaced. Exactly around the same time of the year, a year later, I am encountering the same exact issue again. There is an offensively strong odor from gasoline fumes in and around the vehicle originating in the same place. I did some research on the web, and it looks like there have been hundreds of similar issues reported.

- Fair Lawn, NJ, USA

problem #9

Dec 012013

XC90 6-cyl

  • 164,000 miles
Strong gasoline odor outside and at times inside the car. Researched the issue and found that there was a NHTSA recall in 2010 for this same issue related to the fuel pump, but it only covered certain states. Due to the fact that the vehicle was purchased in Minnesota it was not covered in the recall and I was never notified of the defect. NHTSA investigation faulted a design issue with the fuel pump combined with temperature variations. Apparently 90F to -20F temperature swings in Minnesota was not deemed sufficient to be included or notified about the recall.

- Goshen, NY, USA

problem #8

Jan 162015

XC90

  • 145,000 miles
The contact owns a 2004 Volvo XC90. The contact stated that while in park, the contact noticed fuel vapors emitting from inside and outside the vehicle. In addition, the service engine warning light illuminated. The vehicle was not diagnosed or repaired. The contact was made aware of NHTSA campaign number: 09V483000 (fuel system, gasoline) but the VIN was not included. The manufacturer was notified of the failure. The failure mileage was 145,000.

- Malibu, CA, USA

problem #7

Jan 092015

XC90 6-cyl

  • 170,000 miles
Noticed the smell of fuel while exiting the vehicle. Looked under the vehicle and noticed a fuel leak under the driver's side passenger door. Fuel was leaking at the approximate rate of 3 gallons per 24 hours. Drove the car to the dealer the next morning. Dealer diagnosed the problem as a crack in the fuel sender located on top of the gas tank (not the fuel pump which was replaced under the prior recall). When asked how the leak developed the dealer stated that the plastic fitting cracked due to the cycling of temperatures (same reason for fuel pump failure and recall).

- Wright City, MO, USA

problem #6

Dec 302014

XC90

  • 109,000 miles
The contact owns a 2004 Volvo XC90. While driving approximately 50 mph, the vehicle stalled. The vehicle was able to be restarted. The vehicle was taken to the dealer. The technician diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The contact was notified of NHTSA campaign number: 09V483000 (fuel system, gasoline) however, the VIN was not included. The approximate failure mileage was 109,000.

- Waluku, HI, USA

problem #5

Dec 222014

XC90

  • 133,675 miles
The contact owns a 2004 Volvo XC90. The contact stated that when servicing the vehicle, the technician discovered that the fuel tank was leaking. The vehicle was diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 133,675.

- Miami, FL, USA

problem #4

Nov 192014

XC90 6-cyl

  • 96,266 miles
I just purchased this vehicle used a few days ago and now notice there is a smell of gasoline when we get out of the car. I went on line and discovered that there was a recall for the fuel pump which sits on top of the gas tank. I contacted Volvo and they said to take it to the local dealer in waterbury ct. They told me it would be $800 to repair the part because the warranty ran out in may of this year, and this is November. This is a known safety issue and feel that Volvo should replace the defective part free of charge. Volvo said that the recall only applies to that model located in the South or southwestern us. I am the second owner and have no way of knowing if this car was driven for long periods in those regions. Also, how can they know if their known problem with this fuel pump has not spread to other areas as well?

- Naugatuck, CT, USA

problem #3

Sep 232013

XC90

  • 188,215 miles
The contact owns a 2004 Volvo XC90. The contact stated that while driving 45 mph, he smelled fuel inside the vehicle. The contact pulled the vehicle over and noticed that he had a leak. The vehicle was taken to the dealer but the cause of failure was unknown. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 188,215.

- Chicago, CA, USA

problem #2

Sep 162013

XC90

  • 150,000 miles
The contact owns a 2004 Volvo XC90. The contact stated that upon inspection, fumes coming from the fuel pump entered the vehicle when parked. The vehicle was taken to a dealer and the mechanic stated that the fuel pump had to be replaced. The vehicle was not repaired. The manufacturer was notified. The approximate failure mileage was 150,000.

- Chicago, IL, USA

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