Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Volvo XC90 owners, lightly cleaned up (personal details are redacted by NHTSA).
ADAS, AIR BAR Warning lights/urgent and High Gas fumes coming out from the rear seats when fully filled gas. We had called [phone] and guided us to plug in our VIN [redacted] on www.volvocars.com and nothing showed as far as recall and told us that these recalls expired and our 2005 Volvo are not eligible. 2005 Volvo XC90 that relates to NHTSA Campaign Number: 09V483000, Make: VOLVO Model: XC90 Model Year: 2005 Manufacturer: VOLVO CARS OF N.A. LLC. Mfr's Report Date: DEC 17, 2009 NHTSA CAMPAIGN ID Number: 09V483000 NHTSA Action Number: PE09039 Component: FUEL SYSTEM, GASOLINEELIVERY:FUEL PUMP Potential Number of Units Affected: 136100 Summary: 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, …
Tl* the contact owns a 2005 Volvo XC90. The contact stated that a fuel leak was noticed underneath the vehicle. While driving approximately 57 MPH, the vehicle spun out of control and ended up on the side of the road. In addition, the anti-skid indicator illuminated. The vehicle was taken to Volvo cars bentwood [phone], located at 7700 manchester rd, st. Louis, mo 63143) where the transmission was replaced. The failure recurred and the vehicle was taken back to the same dealer. The technician replaced the fuel cap and stated that the transmission would not be replaced a second time. The manufacturer was made aware of the failures and stated that the warranty was expired. The vehicle was not repaired. The failure mileage was approximately 122,000.
When cranking it stalls and cuts off and after doing it around 10 times it finally cranks then I have to hurry to put in drive to get the motor going in order to keep her crunk and couple weeks ago because this problem she stalled out and I hit a hole in the road and busted the oil pan so she has been parked every since cause I had my daughter in the car and that wasn't a pretty sight since the hit made her nervous now can't get her to get in the car so I need my car fixed and I see it has several recalls and all and it was on a county street once I got it crunk back up it smoked badly till I turned it off and it took four hours for me to get it out the road
Tl* the contact owns a 2005 Volvo XC90. The contact stated that while driving approximately 30 MPH, a fuel odor emitted from the rear of the vehicle as the vehicle lost power and the check engine warning light illuminated. The contact also mentioned that fuel was leaking from the vehicle. In addition, the contact stated that after the vehicle was restarted, the fuel odor recurred. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel line needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 113,000.
Tl* the contact owns a 2005 Volvo XC90. While slowing down or braking, the vehicle suddenly stalled. In addition, the contact had to make several attempts to get the vehicle to start. There was an abnormal odor of fumes inside and outside of the vehicle. The vehicle was taken to an unknown dealer who indicated that the fuel pump assembly needed to be replaced. The vehicle was excluded from NHTSA campaign number: 09V483000 (fuel system, gasoline). The manufacturer was notified of the failure more than two weeks ago, but had not responded to the contact with a solution. The approximate failure mileage was 95,000.
Tl* the contact owns a 2005 Volvo XC90. The contact stated that while driving the vehicle at various speeds, there was a strong fuel odor coming from the vehicle. In addition, the contact stated there was fuel leaking from the rear of the vehicle. The vehicle was driven to the dealer and an independent mechanic on three different occasions where the remedy failed. The vehicle was diagnosed and determined that was the fuel line. The manufacturer was not made aware of the failure. The failure mileage was 121,000.
Tl* the contact owns a 2005 Volvo XC90. During an inspection, the technician diagnosed that the vehicle had a strong odor of fuel near the engine. The vehicle was not diagnosed or repaired. The contact believed that the vehicle May be included in NHTSA campaign number: 09V483000 (fuel system, gasoline); however, the VIN was excluded. The manufacturer was not notified of the failure. The failure mileage was 131,792.
Tl* the contact owns a 2005 Volvo XC90. The contact stated that the check engine warning light illuminated. In addition, the vehicle jerked and stalled while driving. The vehicle was taken to a independent mechanic where it was diagnosed that the fuel pump injector needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 98,000.
Tl* the contact owns a 2005 Volvo XC90. The contact stated that there was a fuel odor emanating from the vehicle while driving at various speeds. The odor caused the contact to sustain occasional headaches. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 137,000.
All the vehicle lights will come on over the dash and the wheel locks then it shuts off while I am driving. This is so unsafe for my family. I am not sure why there is not a recall for my VIN # when google clearly states that this is a hazard and that there are recalls for this problem.
Related recalls
Fuel system, gasoline › Delivery › Fuel pump
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,…
Remedy: Dealers will inspect the fuel pump installed in the vehicle, and if necessary replace the fuel pump with a part of a modified design. This service will be performed free of charge.
Fuel System complaints in other XC90 years
Frequently asked questions
How common are fuel system problems on the 2005 Volvo XC90?
NHTSA has 33 complaints about the fuel & propulsion system of the 2005 Volvo XC90, 15% of the model year's 223 complaints. The component named most often is delivery › fuel pump (2 mentions).
Is there a recall for 2005 Volvo XC90 fuel system problems?
Yes — NHTSA recall 09V-483 (fuel pump, Dec 18, 2009). Recall repairs are free at authorized dealers.
At what mileage do 2005 Volvo XC90 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 115,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.