Recalls: Volvo Mk.1 XC90
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Volvo Mk.1 XC90
Volvo XC90: seatbelt attachment points not fitted correctly
In October 2003, a recall was issued for Volvo Mk.1 XC90 vehicles due to the seatbelt attachment points for the second and third row seats potentially not having been fitted or tightened correctly. The recall required that the vehicles be inspected and, if required, the screws were to replaced and tightened to specification. The recalled vehicles had serial numbers in the range 0000408 to 0042565 (PRA 2003/6553).
2004 model year Volvo XC90: faulty front wheel speed sensors
In November 2003, a recall was issued for model year 2004 Volvo XC90 vehicles due to potentially faulty front wheel speed sensors. As a result, the functionality of several components, including the brakes, engine, transmission and torque distribution may be affected. Furthermore, the ABS may not activate under braking and the ABS may illuminate. The recall required that the front wheel speed sensors were replaced with sensors of a modified design (PRA 2003/6561).
2005-06 model year Volvo XC90: potential fire hazard
In November 2005, a recall was issued for model year 2005 and 2006 Volvo Mk.1 XC90 vehicles with turbocharged six-cylinder engines. For the affected vehicles, there may be a short circuit and the wire harness may overheat. If parked, this may cause smoke to appear from under the bonnet and/or it may not be possible to start the vehicle; if driving, electrical power may be lost, resulting in the warning lights illuminating or the engine stalling. The recall required that the distance between the B+ terminal and the starter motor be increased by adjusting the terminal (PRA 2005/8161).
2006 model year Volvo XC90: incorrect tyre placard label
In March 2006, a recall was issued for model year 2006 Volvo XC90 vehicles due to the fitment of an incorrect tyre placard label (PRA 2006/8405).
2003-06 model year Volvo XC90: outer tie rod end joints could fracture
In May 2006, a recall was issued for certain model year 2003 to 2006 Volvo XC90 vehicles due to potential fracture of the outer tie rod end joints on the steering gear; in extreme cases, this could lead to a loss of steering control. For the affected vehicles, the outer ball joints were to be replaced (PRA 2006/8500).
2007 model year Volvo XC90: cooling fan control unit counld fail
In March 2007, a recall was issued for model year 2007 Volvo XC90 vehicles due to the metal cover of the electric cooling fan control unit not having the specified corrosion protection. As a result, the cover may corrode, leading to moisture ingress and electrical malfunction; the malfunction may result in high engine temperatures, producing high engine temperature readings in the instrument gauge and a warning message in the Driver Information Module (PRA 2007/9094).
2003-04 Volvo XC90: crankcase ventilation leakage
In March 2007, a recall was issued for model year 2003 and 2004 Volvo XC90 vehicles fitted with six cylinder engines. In some vehicles, the Nipple PCV may crack or come loose of the hose, resulting in an air leakage from the crank case ventilation system (PRA 2007/9150).
2007-08 model year Volvo XC90 3.2i: climate control system
In December 2007, a recall was issued for model year 2007 and 2008 Volvo XC90 vehicles fitted with 3.2-litre petrol engines. For these vehicles, the climate control system may have limited operation after engine start-up and the defrost function may not work (PRA 2007/9714).
2007-08 model year Volvo XC90 D5: potential loss of steering assistance
In March 2008, a recall was issued for model year 2007 and 2008 Volvo XC90 vehicles fitted with 2.4-litre diesel engines. For these vehicles, the power steering hose may come into contact with the engine cooling fan due to an insufficient retaining clip (PRA 2008/9865).
2007-09 model year Volvo XC90 D5: potential loss of steering assistance
In December 2009, a recall was issued for model year 2007 to 2009 Volvo XC90 vehicles fitted with the D5 diesel engine and in the VIN range 0371138 to 0523482. In these vehicles, the power steering hose may come into contact with the engine cooling fan – this could cause the hose to chafe and result in a sudden drainage of power steering oil and a loss of power steering assistance (PRA 2009/11270).
2009-10 model year Volvo XC90 D5: potential loss of steering assistance
In July 2015, a recall was issued for 2009 and 2010 model year Volvo XC90 vehicles with five-cylinder turbo-diesel engines which had serial numbers (i.e. the last six digits of the VIN) in the range 512232 to 545469. In these vehicles, the power steering hose may come into contact with the engine cooling fan – this could damage the power steering hose, causing it to leak and cease providing power steering assistance. In turn, reduced steering ability could pose a hazard to the driver and other road users (PRA 2015/14803).
2010 model year Volvo XC90 3.2i: potential fuel leak
In April 2010, a recall was issued for model year 2010 Volvo XC90 vehicles fitted with a 3.2-litre petrol engine and in the VIN range 546203 to 553594. For these vehicles, a manufacturing defect in the fuel pressure line may result in a fuel small and/or fuel seepage. Because the fuel line was working under constant pressure, seepage could develop into a greater leakage. At worst, the leakage may combine with an external ignition source to cause a fire in the right front wheel house area (PRA 2010/11608).
2010 model year Volvo XC90 D5: potential fuel leak
In July 2010, a recall was issued for model year 2010 Volvo XC90 vehicles fitted with a 2.4-litre diesel engine and in the VIN range 551239 to 553207. In these vehicles, a manufacturing defect in the fuel pressure line may result in a fuel small and/or fuel seepage. Because the fuel line was working under constant pressure, seepage could develop into a greater leakage. At worst, the leakage may combine with an external ignition source to cause a fire in the right front wheel house area (PRA 2010/11809).
2010-11 model year Volvo XC90: loss of power steering assistance
In May 2011, a recall was issued for 2010 and 2011 model year Volvo XC90 vehicles in the VIN range 553910 to 576645. In these vehicles, a leak from the steering gear may drain the power steering oil, generating noise and gradually decreased power steering assistance. At worst, however, sudden drainage of the power steering oil may cause a sudden loss of power steering assistance (PRA 2011/12577).
Problems and faults: Volvo Mk.1 XC90
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
2007-11 Volvo XC90 3.2: excessive oil consumption, white exhaust smoke and low/uneven idle
In April 2012, Volvo issued Technical Journal 24643 for 2007-11 Volvo XC90 3.2 vehicles that had engines manufactured prior to 4 May 2011. According to the Technical Journal, these vehicles may exhibit the following symptoms:
- Low oil level;
- Excessive oil consumption;
- Poor idle quality;
- White smoke from the exhaust;
- An oil smell; and/or
- Illumination of the yellow warning symbol and ‘Low oil level’ or ‘Oil level low’ messages in the Driver information Module (SIM).
To determine if the vehicle had an oil consumption condition,
- The engine should be inspected for external leakage on and around the engine, especially around the cylinder head/cam cover/timing cover area. If an external leakage was present, then the following steps were not applicable;
- An oil consumption test could be performed if there was no prior record of low oil levels and oil being added between service intervals;
- The spark plugs were to be examined for evidence of previous oil over-filling since this could be the cause of DTCs related to oil consumption (specifically DTC P030000 and/or P030600). As the Technical Journal acknowledged, these engines were susceptible to over-filling since it was difficult to easily check the oil level with the dipstick;
- A cylinder leakage test was to be performed to determine if oil consumption was coming from an area other than the cam cover;
- If the cylinder leakage tests were OK and if the spark plug from cylinder #6 had more soot than the others, this suggested that the cam cover was not properly sealed from the factory. If so, the cam cover was to be removed so that the sealing surface could be inspected. If the sealing surface was discoloured by oil, it was most likely that there was a leak between the cam cover and the cylinder head in the area facing the positive crankcase ventilation (PCV) channel which connected the breather box and the PCV gallery. To fix, the cam cover was to be re-sealed. The cam cover seal was improved at engine production date 15 April 2010 (15041000001); and,
- If the cylinder leakage tests were OK and there was a spark plug from a cylinder other than #6 which had more soot than the others, then the valve guides were to be inspected. Valve guide leakage was most commonly found when there was excessive white smoke from the exhaust and had been observed on engines with build dates before 4 May 2011 (040511B01272). Each valve guide was to be tested by removing the cam cover, removing the valve tappets, plugging all but one intake port and plugging all intake ports, injector ports and the PCV inlet. Air pressure could then be applied to one intake port at a time and, by using automatic transmission fluid (ATF) for colour differentiation, ripples or bubbles in the ATF would indicate a leak that required the cylinder head to be replaced.
Please note that the testing procedure described above differs for models that have B6324S4 PZEV (‘Engine 94’) or B6324S2 PZEV (‘Engine 96’) engines – these may require new pistons and oil control rings. For information on those engines, please refer to Technical Journal 24643.
2003-05 model year Volvo XC90: potential cracks in fuel pump flange
In 2010, Volvo UK issued a ‘non-code action’ for 2003-05 model year Volvo XC90 vehicles that had petrol engines. In these Volvo XC90 vehicles, certain environmental conditions, i.e. hot climate and temperature cycling, combined with varying fuel quality could cause the fuel pump to develop cracks in the fuel pump flange. If this occurred, the driver may detect a fuel smell, while a fuel leak could also occur and pose a fire hazard (NCA/2010/019). In the USA, an official safety recall was issued for this concern (NHTSA Campaign Number 09V483000).
Volvo XC90 V8 (B8444S): balance shaft bearing failure
The 4.4-litre B8444S V8 engine has a counter balance shaft in the engine’s ‘V’, between the cylinder banks. Washing the engine bay with water can cause water to accumulate between the cylinder banks and cause a sealed bearing which supports the balance shaft to corrode. Once the bearing fails or seizes, the bearing can begin to rotate within its housing and damage the engine casting. The main symptoms of bearing damage are unusual engine noises and rough running. To fix, the bearing needs to be replaced, though this requires the inlet manifold and at least one cylinder head to be removed for access.
If not repaired, the balance shaft will rattle and wear against the mount point on the opposite side where the timing chain is located. Eventually, the sprocket which drives the balance shafts can wear out, the timing chain can lose tension and this can affect the engine’s timing such that the pistons and valves may collide. If this occurs, Volvo’s repair procedure advises that the engine needs to be removed from the engine bay so that the cylinder heads can be removed – this makes repairs particularly expensive.
From engine no. 6833 (introduced in late 2005 or early 2006), two changes were made to avoid this problem:
- Drainage holes were introduced to the engine casting so that water would not accumulate in the vicinity of the bearing; and,
- An improved bearing was introduced.
AustralianCar.Reviews understands that Volvo has issued a technical bulletin advising dealers not to pressure wash or steam clean the B8444S engine due to this problem.
Volvo XC90: engine won’t start
The Volvo XC90’s engine may not start if the fuel level is low and the vehicle is parked facing downhill due to the design of fuel pump. Later models had a redesigned pump with an anti-siphon valve.
Volvo XC90: irregular engine performance
In 2010, Volvo UK issued a ‘non-code action’ for Volvo XC90 vehicles because of ‘irregular engine performance’ (NCA/2010/004); no further information was provided.
Problems and faults: Volvo Mk.1 XC90
- A squealing or rubbing noise that occurs after driving through a puddle is caused by the exhaust pipe temporarily warping and touching the driveshaft; an additional exhaust hanger can be fitted to solve the problem.
- The battery may drain overnight if the ‘infotainment’ system prevents the central control module from entering ‘sleep’ mode.
- The climate control air conditioning may cycle from full hot to full cold every 10 seconds or so if the control module forgets its calibration and continuously tries to recalibrate itself.
- The power adjustable front seats may rock back and forth – new gas shocks/struts are available to fix this problem.
- The upper tailgate may not open because the release cable comes loose from its retaining clip.
- The windscreen wiper arms’ splines can be damaged if the wipers are turned on while the blades are frozen to the windshield; improved arms were subsequently released.
- Excessive air flow from the air conditioner to the vent near the driver’s foot is corrected by fitting a piece of foam to create a restriction.
- For early XC90 models, unwanted noises may come from the speakers if an auxiliary music player was used. A revised cable for the wiring harness was subsequently released to fix this problem, though the audio module may also require replacement.
