Problems · by component
2004 Volvo XC90 fuel/propulsion system problems
34 owner complaints to NHTSA about the 2004 Volvo XC90 cite fuel/propulsion system, 7% of all 462 complaints for this model year.
Complaints
34
7% of all complaints
Crashes
0
Reported by owners
Fires
0
Reported by owners
Injuries
0
Reported by owners
What owners say about the fuel/propulsion system
Verbatim from NHTSA complaints, newest first
“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 that’s been going on for a year now when I drive at 60 miles an hour I’ve had it looked at and no one seems to know what that issue is”
“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.”
“THE FUEL PUMP UNDER THE BACK SEAT IS CRACKED AND LEAKING FUEL. THIS IS REFERENCED IN NHTSA RECALL NUMBER 09V483000. O'STEEN VOLVO IN JACKSONVILLE REFUSES TO ACKNOWLEDGE THERE WAS EVER A PROBLEM WITH THIS. IT IS ALL OVER THE INTERNET.THE VEHICLE IS NOT DRIVEABLE AS IS. THE CAR IS SOAKED WITH GASOLINE. APPARENTLY THE FUEL PUMP HOUSING DRIES OUT FROM HEAT AND CRACKS. WE NEED SOME HELP HERE. IT WOULD BE BETTER IF SOMEONE IN SAINT AUGUSTINE FLORIDA COULD DO THIS RECALL WORK FOR US AS WE REALLY DON'T WANT TO DEAL WITH O'STEEN AFTER THEY HAVE BLOWN US OFF.”
“A FEW YEARS AGO I RECEIVED A EXTENDED WARRANTY FOR A FUEL PUMP RECALL. MY FUEL PUMP IS NOW LEAKING GAS AND FILLING THE CAR WITH GAS FUMES. WHEN I CALLED THE VOLVO DEALER I WAS TOLD THAT THE EXTENDED WARRANTY WAS NO LONGER VALID AND IT WOULD COST $1,000.00 TO HAVE IT FIXED. I CALLED THE VEHICLE SAFETY HOTLINE AND WAS TOLD THAT MY VIN NUMBER WASN'T INCLUDED IN THE RECALL AND I WOULD NEED TO FILE A COMPLAINT. THE CAR IS 16 YEARS OLD AND IS IN GOOD CONDITION I FEEL THAT AS VOLVO KNOWS THAT THE FUEL PUMP IS A SAFETY ISSUE THAT ALL CARS THAT HAVE THE SAME FUEL PUMP ISSUE THAT ARE STILL DRIVING THE HIGHWAYS SHOULD BE INCLUDED IN THE RECALL. NOTHING HAPPENED OTHER THAN THE HEAVY FUEL SMELL THAT FILLS THE CAR WHEN DRIVING AND THE FUEL CAN BE SMELLED OUTSIDE OF THE CAR AFTER IT HAS BEEN TURNED OFF. I HAVE HAD THE CAR FIXED BUT THINK THAT THE FUEL PUMP ISSUE SHOULD STILL BE ADDRESSED. I DIDN'T HAVE AN ACCIDENT AND THERE WAS NO FIRE, BUT THERE COULD HAVE BEEN.”
“RAW GAS SMELL. TOLD BY DEALER MAY BE DANGERS TO DRIVE AND PARK OUT OF GARAGE SO FUMES DON'T ACCUMULATE. GARAGE HAS NATURAL GAS HEAT AND GAS WATER HEATER. SOME CARS SOLD IN OTHER STATES HAVE HAD RECALLS, UNDER VOLVO RECALL # 220. THIS CAR HAS BEEN USED IN SOME STATES NAMED IN SUMMER MONTHS. I AM ORIG OWNER.”
“BOUGHT THE VEHICLE WITH 112,000 MILES ON IT, IT HAS A GAS LEAK TRICKLING DOWN THE SIDE OF THE GAS TANK, PROBABLY A BAD SENDING UNIT, FUMES ARE BAD SOME DAYS BUT WORSE ON WARMER DAYS. THE TRANSMISSION FAILED ONE DAY WITH NO WARNING OR LIGHT, IT JUST LOST MOMENTUM AND FAILED TO ENGAGE IN DRIVE. I THINK THIS IS DUE TO THE POOR ENGINEERING DESIGN VOLVO USED. THIS MODEL IS THE T6 WITH THE GM 4T65E TRANSMISSION WHICH IS WIDELY KNOWN TO FAIL EVEN AT LOW MILES. I THINK A FULL SAFETY RECALL SHOULD E SANCTIONED FOR ALL MODEL YEARS WITH THESE HORRIBLE PROBLEMS”
Showing 6 of 34 reports. Read every report on NHTSA.gov.
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 29, 2026NHTSA vehicle page
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.