Fuel System complaints by model year
| Year | Complaints | Share of year's complaints | Typical mileage |
|---|---|---|---|
| 2024 | 1 | 3% | — |
| 2023 | 6 | 15% | 1,000 miles |
| 2022 | 9 | 30% | — |
| 2021 | 6 | 15% | — |
| 2020 | 3 | 9% | — |
| 2019 | 2 | 5% | 80,000 miles |
| 2018 | 6 | 12% | 23,000 miles |
| 2017 | 7 | 9% | 150,000 miles |
| 2016 | 13 | 7% | 31,000 miles |
| 2013 | 1 | 9% | 110,000 miles |
| 2011 | 1 | 5% | 2,000 miles |
| 2010 | 4 | 33% | 125,000 miles |
| 2009 | 1 | 14% | — |
| 2008 | 3 | 10% | — |
| 2007 | 3 | 8% | — |
| 2006 | 5 | 9% | 132,000 miles |
| 2005 | 33 | 15% | 115,000 miles |
| 2004 | 77 | 17% | 101,000 miles |
| 2003 | 10 | 11% | 111,000 miles |
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
The contact owns a 2023 Volvo XC90. The contact stated while driving 65 MPH, the low fuel warning light illuminated and the vehicle decelerated, lost motive power, and stalled. The contact attempted to restart the vehicle, but the vehicle would not restart. The vehicle was towed to the dealer. After several attempts to restart the vehicle, the dealer was able to restart the vehicle and stated that no failure was found. The manufacturer was not contacted. The failure mileage was 1,000. The VIN was not available.
On May 18, 2023, the vehicle was not driveable and it was not able to be taken out of the park mode. The vehicle had no power so the engine would not start regardless of what the tow truck driver tried. The car had to be pulled onto the tow truck so the tires did not move. On June 10, 2023, Due to a backlog. The Volvo dealership was finally able to look at the vehicle. They stated "error codes in the computer indicate an internal defect in the high-voltage battery. Even after consultation with Volvo technical support, we cannot avoid removing and opening the battery to replace a part inside the battery." Due to a backlog and waiting for parts, they stated it would be 6 weeks before they could repair. …
Propulsion Service Required message one week after we picked up our new car. Three weeks later----check engine light. Soon after another Propulsion Service Required. Each time, our dealership reset the computer. Three months into ownership, on I-84, traveling 75 mph in the far left lane: turtle mode light, loss of power, no propulsion, able to just get off the freeway on the left. Two hour wait for assistance on side of freeway in 98 degree heat. Dealership kept car for 40 days: replaced BDU, AC compressor, IGM. Similar accounts of turtle mode and power failure from other 2022 Volvo owners on speedswede.com. We are not driving our car. Someone is going to get run over by another vehicle if Volvo doesn't address the problem.
I was driving up hill at night with my kids in the car and my vehicle had a propulsion error and my car shut off on a blind corner. I couldn't even put it in neutral and push it to the side. I was stranded without any way to move my vehicle. Multiple cars were inches away from hitting me. This is a known issue with 2022 XC90 recharges. Volvo said they did a software update and this should fix my vehicle but unfortunately that does not seem promising as many others are still experiencing issues. Scared for my life driving my vehicle again.
The contact owns a 2021 Volvo XC90. The contact stated that upon shifting to Drive(D) while the vehicle was on an incline, the vehicle rolled back before moving forward as intended. The contact stated that the failure had been recurring, causing the vehicle to hit a garage door and a brick mailbox on two different occasions. The contact stated that the tailgate was opened and sustained a dent when the vehicle hit the garage door. The contact stated that upon shifting to Reverse(R) on a decline, the vehicle rolled forward before reversing as intended. The contact stated that the failure had caused the vehicle to hit two pedestrians. There were no reported injuries. No police report was filed. The vehicle was taken to the dealer on several occasions, and several unknown repairs were performed; however, the failure persisted. …
Unintentional acceleration.First, I was in line at car wash proceeding slowly ahead as directed in line. Foot on accelerator lightly moving, when car surged rapidly hitting back end of Tesla about 6-8 ft ahead (2/26/26 12:30pm) Impact strong enough to push Tesla into truck hitch damaging it front of it as well. Applied brake, but impact was too rapid. Second incident with my Volvo was a month later(3/22/26 about 10:30 am) and my husband was driving. . Made right turn on green light and started to accelerate when it revived and surged forward until applied brake. Dealer could not replicate. No codes but repair shop had to recalibrate after 1st incident and may have lost code on 1st incident(wreck). Now that insurance knows what happened, I don't know if they will intervene. hopefully. No warnings went off or messages. Airbag did not deploy. …
I was driving the speed limit on the highway in my Volvo 2020 XC90 which was less than one year old. The vehicle lost acceleration power and then an engine performance light came on, then a check engine light. I pulled over immediately and my car engine caught fire under the hood. The entire front of vehicle was engulfed in flames within minutes. There were approximately 11k miles on the car and it had never been maintenanced or worked on in any way that would have caused an engine fire. It was clearly a fuel line fire and Volvo did not properly investigate. My insurance company said it was a fuel line fire but could not get information from the black box because it was destroyed. This car is incredibly unsafe and should be recalled. I have multiple videos and case files concerning this "thermal event". …
In early December (2025), I experienced Hybrid System Failure, with the vehicle showing this fault in the dashboard and the check engine light coming on. I took it to the dealership, as the hybrid system is still within warranty, and they diagnosed a failed hybrid battery module. They said I could continue to drive the care in combustion-only mode and would order the module. Having heard nothing, I checked in early January and was told the module would not be available until May or June of 2026. I escalated to Volvo corporate. They opened a case and keep promising to have a manager reach out to update me, but they have failed to follow-through for almost a month. I am now faced with the prospect of operating an impaired vehicle that can't pass an emissions test (and which is under warranty) for more than half a year.
Related recalls (3)
Fuel system, gasoline › Delivery › Fuel pump
Volvo Car USA, LLC (Volvo Car) is recalling certain 2019-2020 V90, XC60, S60, V60, V60CC, S90, V90CC, S90L, and XC90 vehicles. The low-pressure fuel pump can blow a fuse and fail.
Remedy: Dealers will replace the fuse, free of charge. Owner notification letters were mailed July 2, 2021. Owners may contact Volvo Car customer service at 1-888-458-1552. Volvo Car's number for this recall is R10100.
Fuel system, gasoline › Delivery
Volvo is recalling certain model year 2010 xc90 vehicles. A leak May develop in the fuel line between the line and a connector.
Remedy: Dealers will inspect the date code printed on the fuel line and replace the fuel pressure line if it falls within the recalled range free of charge. The recall began on April 23, 2010.
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.
NHTSA investigations
Fuel pump leak
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…
Frequently asked questions
Which Volvo XC90 years have fuel system problems?
By NHTSA complaints, the 2004 (77), 2005 (33), 2016 (13), 2003 (10) and 2022 (9) model years. Fuel System complaints make up 17% of all complaints for the 2004.
Is there a recall for Volvo XC90 fuel system problems?
Yes — 3 recalls, including 21V-414 (fuel pump, Jun 2, 2021); 10V-147 (delivery, Apr 16, 2010); 09V-483 (fuel pump, Dec 18, 2009). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Volvo XC90 fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 102,000 miles; 16% happened before 50,000 miles.
What part fails most often?
Owners most often name the delivery › fuel pump (13 mentions), followed by the delivery › hoses, lines/piping, and fittings (2).
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.