NHTSA Defect Investigations for the 2004 Volvo XC90

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2004 Volvo XC90, both ongoing and closed, are listed below:

  1. Central Electronic Module Failure NHTSA Preliminary Evaluation #PE10025

    • Status:
      CLOSED
    • Date Opened: July 20, 2010
    • Date Closed: November 22, 2010
    • Recall: no recall issued

    Component(s): Electrical System

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE10025 »

  2. FUEL PUMP LEAK NHTSA Preliminary Evaluation #PE09039

    Component(s): Fuel System, Gasoline
    Fuel System, Gasoline:Delivery
    Fuel System, Gasoline:Delivery:Fuel Pump
    Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

    Summary: 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).

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE09039 »

  3. WINDSHIELD WIPER ARM PERFORMANCE NHTSA Preliminary Evaluation #PE05064

    Component(s): Visibility:Windshield Wiper/Washer:Linkages

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE05064 »

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