Problems · by component

2004 Volvo XC90 fuel system, gasoline problems

40 owner complaints to NHTSA about the 2004 Volvo XC90 cite fuel system, gasoline, 9% of all 462 complaints for this model year. NHTSA also lists 1 recall on this component.

Complaints
40
9% of all complaints
Crashes
0
Reported by owners
Fires
0
Reported by owners
Injuries
1
Reported by owners
01 —Owner reports

What owners say about the fuel system, gasoline

Verbatim from NHTSA complaints, newest first
“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.”
Owner complaint to NHTSAFiled Nov 9, 2022Fuel system, gasolineODI 11492882
“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.”
Owner complaint to NHTSAFiled Oct 3, 2022Fuel system, gasolineODI 11487737
“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. *TR”
Owner complaint to NHTSAFiled Nov 2, 2016Fuel system, gasolineODI 10923903
“TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING, THERE WAS A STRONG ODOR OF FUEL IN THE VEHICLE. THE CONTACT NOTICED FUEL LEAKING ONTO THE GROUND. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM). THE FAILURE MILEAGE WAS 132,000.”
Owner complaint to NHTSAFiled Jul 29, 2016Fuel system, gasolineODI 10891587
“2004 VOLVO XC90. CONSUMER WRITES IN REGARDS TO A BROKEN FUEL PUMP AND LEAKING GAS. *SMD THE CONSUMER NOTICED A STRONG GAS SMELL IN THE GARAGE. THE CONSUMER DISCOVERED RECALL # 09V483000. HOWEVER, HE WAS NEVER INFORMED. *JB”
Owner complaint to NHTSAFiled Mar 10, 2015Fuel system, gasolineODI 10677140
“SMELLED GASOLINE, TOOK IT TO A SHOP, THEY FOUND FUEL PUMP CRACKED, REPLACED FUEL PUMP. THEN WE FOUND OUT THE WAS A RECALL IN SOUTHERN STATES FOR THIS PROBLEM SPECIFICALLY. WE LIVE IN THE NEW ENGLAND AREA AND WAS TOLD IT WOULD NOT BE CONSIDERED UNDER THE RECALL. I FEEL COMPLETELY WRONGED IN THIS SITUATION. THE RECALL WAS SPECIFIC TO HEAT CYCLING. NO WERE IN THE US IS THIS MORE APPARENT THAN NEW ENGLAND. *TR”
Owner complaint to NHTSAFiled Dec 5, 2014Fuel system, gasolineODI 10662428

Showing 6 of 40 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 29, 2026NHTSA vehicle page
02 —Related recalls

1 recall on this component

Fuel system

Free remedy

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.

Fuel system, gasolineReported Dec 18, 2009NHTSA 09V483000
Data from NHTSA Recalls API · synced Oct 29, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.