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
2004 Volvo XC90 fuel system problems
77 complaints (17% of all complaints for this car). Typical mileage when it fails: 101,000.
- owner complaints
- 77
- of this car's complaints
- 17%
- typical mileage
- 101,000
- crashes
- 0
- recalls
- 1
Which part fails
- Delivery: fuel pump8
- Delivery: hoses, lines/piping, and fittings1
At what mileage
Complaints by mileage at the time of the problem.
Volvo XC90 fuel system problems in other years
Specific symptoms reported on the 2004 Volvo XC90 fuel system
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Related recalls
Fuel system, gasoline: delivery: fuel pump
- What is wrong
- 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.
- Risk
- If the condition occurs vehicle owners may notice fuel smell and/or fuel leak which, in the presence of an ignition source, could result in a fire.
- 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. The safety recall began on january 15, 2010. Owners may contact volvo at 1‑800‑458‑1552.
Recall number 09V483000 · Recall details
Related 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 frequency of complaints/repairs is higher in the hot climate states. Volvo will recall and replace the fuel pump with a part of a modified design/material in approximately 136,100 my2001-2004 s60/v70/xc70, my2001-2005 s80 and my2003-2005 xc90 vehicles in 19 states.these states include al, az, ar, ca, fl, ga, hi, ky, la, ms, nv, nm, nc, ok, sc, tn, tx, ut, va and the us territories.in addition, volvo will extend the warranty coverage to 10 years/150,000 miles on approximately 190,000 vehicles for the remaining states.this recall/extended warranty program supersedes previous 07v‑152/tnn 23-198 program on my2001-2002 vehicles.this investigation is closed (see recall campaign 09v‑483).
PE09039
What 2004 Volvo XC90 owners say
Most recent owner complaints, unedited.
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 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 the federal safety agency 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.
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 the federal safety agency Campaign Number: 09V483000 (Fuel System, Gasoline). The failure mileage was approximately 212,000.
Inside smells of gasoline after starting, and while driving. Persistent. Nauseating while driving. Windows must be let down while driving.
The fuel pump under the back seat is cracked and leaking fuel. This is referenced in the federal safety agency 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
We smelled a gasoline odor and the "check engine" light came on so we took our volvo to a dealer to inspect. They said that there was a crack in the top of the fuel tank. I am the original owner and have taken meticulous care of this vehicle so that sounded very strange. The car only has 108,000 miles in 15 years. I now see where this model was recalled for fuel pump replacement several years ago but it was while I was out of the country for two years (2004-2006) on a project for my employer. I had my parents keep the car while I was gone and none of us received the notice about the recall. Shouldn't volvo still have to honor this recall since I was not aware of it at the time? According to your recall campaign 09v‑483 my car would have been included in the recall group, although my VIN number doesn't show up under the recalls now...could it be that the campaign is over so it doesn't show up now? Volvo customer care knew about this problem when I called them on friday but are hemming and hawing about doing anything about it. It seems a cracked fuel tank could catch fire.
Questions about the 2004 Volvo XC90 fuel system
Does the 2004 Volvo XC90 have fuel system problems?
Owners have filed 77 complaints about the fuel system of the 2004 Volvo XC90, 17% of all its complaints.
At what mileage do 2004 Volvo XC90 fuel system problems start?
The typical (median) mileage in owner complaints is 101,000 miles.
Was there a recall on the 2004 Volvo XC90 fuel system?
Yes, 1 recall: 09V483000. Check your VIN to see if your car still needs the free repair.
What year does the Volvo XC90 have the most fuel system problems?
The Volvo XC90 model years with the most fuel system complaints are 2004 (77 complaints), 2005 (33 complaints) and 2016 (13 complaints).
Is there a class action lawsuit over the Volvo XC90?
Yes. New class action says Volvo's Google-based infotainment screens freeze and take climate and rearview camera with them (November 9, 2026).
Other 2004 Volvo XC90 problems
Electrical 158Transmission 145Engine 52Lights 33Airbags 31Suspension 23Steering 20Brakes 19Acceleration 17Body 14Driver assistance 12Wheels 10Seat belts 6Tires 6Visibility 6Locks 4Seats 2
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