Volvo XC90 fuel pump problems

Filed Mar 23, 2026 · Fuel system · FL

I am reporting a failure of the fuel pump system in my Volvo vehicle, which currently has approximately 60,000 miles. The failed component is available for inspection upon request. The issue was confirmed by an authorized Volvo dealership, which diagnosed the fuel pump as defective and requiring replacement. This appears to be a premature failure given the mileage and proper maintenance of the vehicle. This failure presents a serious safety risk. A faulty fuel pump can cause the vehicle to stall unexpectedly while driving, increasing the risk of a crash, especially at highway speeds or in traffic. Loss of engine power without warning places not only the driver and passengers at risk, but also other motorists on the road. Prior to the failure, the vehicle experienced symptoms consistent with fuel system issues, including difficulty starting and intermittent performance irregularities. These symptoms escalated until the vehicle became unreliable to operate. The problem has been confirmed by the manufacturer’s authorized service center, and the vehicle has been inspected accordingly. No external factors or misuse contributed to this failure. It is my understanding that Volvo has issued recalls and/or acknowledged similar fuel pump defects in other vehicles of comparable models and years. Based on the nature of this failure and its alignment with known issues, I believe this vehicle should be evaluated for inclusion under an existing recall or be subject to further investigation. Given the safety implications of fuel system failures, I respectfully request that this issue be formally reviewed to determine whether a broader defect trend exists that could impact other vehicles. The failure occurred at relatively low mileage and under normal operating conditions, raising concern of a systemic defect rather than normal wear and tear.

Filed Nov 22, 2024 · Electrical, Engine · NV

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

Filed Jun 20, 2023 · Fuel system · NY

On 6/12/23, I was driving on a highway in New York State when I heard a bump under my car and I thought it was a rock. Nothing flashed on my dash to warn me that something serious had happened. Another driver pulled next to me and shouted out of the window, "YOUR CAR IS SPILLING GAS OUT OF THE BOTTOM OF YOUR CAR, PULL OVER OR YOUR CAR MAY CATCH FIRE." As I was near an exit, I got off the highway, and there was a service station right there. When I got out of the car, with the ignition off, I saw gas coming from the bottom of my car like a faucet (Tank was 1/2 full). The service people told me to get away from the car and they tried to catch the gas as it was going all over the road and parking lot. My car was towed by Volvo to a dealer and they found that there was a 4 inch gash in my gas tank, likely caused by a piece of metal that fell from a truck. It took a week to fix my car, replace the gas tank, fuel pump and everything associated with the fuel system. It cost me $3,800 to fix. My car had less than 9,000 miles on it. When I approached VOLVO USA headquarters and asked that they try to reimburse me they replied it was an ACT OF GOD, and they would not cover any of it. My insurance would not cover it as it was not an accident. My complaint is that this car had no warning system within the high tech dashboard to alert me that my car was in trouble. Had it not been for the stranger on the road, I would not have known, as my A/C was on and my windows were closed. I did not smell the gas until I left the car. It is a flaw of this car that there was no warning system in place to let me know that my gas tank was breached. My dash flashes signals when my windshield wiper fluid is low. I am appealing to the National Highway Safety Commission to report this to Volvo, and not only try to get me paid back some of the money I spent, but to upgrade their safety alert system so someone does not get killed in a freak incident like this

Filed Jun 2, 2023 · Fuel system · CA

ADAS, AIR BAR Warning lights/urgent and High Gas fumes coming out from the rear seats when fully filled gas. We had called 800‑458‑1552 and guided us to plug in our VIN [XXX] 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 the federal safety agency Campaign Number: 09V483000, Make: VOLVO Model: XC90 Model Year: 2005 Manufacturer: VOLVO CARS OF N.A. LLC. Mfr's Report Date: DEC 17, 2009 the federal safety agency CAMPAIGN ID Number: 09V483000 the federal safety agency 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, 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. Consequence: 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 IS EXPECTED TO BEGIN DURING JANUARY 2010. OWNERS MAY CONTACT VOLVO AT 1‑800‑458‑1552. My wife and I had purchased our Volvo XC90 in 2005, here in CA. Six months ago everytime we filled up the gas tank, we would smell a heavy fumes of gas as it was coming from the inside of the vehicle. We had called the Volvo 800 number above and guided us to plug in our VIN [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA

Filed May 16, 2023 · Fuel system · CO

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.

Filed May 16, 2023 · Engine, Fuel system · FL

My XC90 had the oil consumption issue that I started reporting at 50K miles and Volvo finally performed a piston ring replacement at 80K miles under a service action. Fuel injectors were also replaced by the Dealer. On our first long distance trip from Tallahassee to Atlanta, the car lost all power and stopped on I-75, almost killing us. It had to be towed and the dealer says that the engine was flooded by fuel due to fuel pump module failure causing fuel injectors to stay activated and engine needs to be replaced. I believe that the issue was caused by the repair not being done correctly or the time it took Volvo to take responsibility for the oil consumption issue and subsequent repair.

Filed Dec 13, 2022 · Fuel system · AZ

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. This Recall Was Done for a 2004 Volvo xc90 . I am currently Experiencing the same problem with my 2007 volvo Xc90 AWD. Every time, I fill up to 1/2 a tank or full , I start to smell the fumes inside the vehicle . I took it to get inspected , and the mechanic said the fuel pump assembly usually cracks and the vapor goes inside the cabin. I personally think this is not safe for us drivers or the passengers. living in Arizona with high temperatures usually all plastic have wear and tear , but On the fuel pump housing ? It's not where we want it.

Filed Apr 26, 2021 · Fuel system · 244,777 miles · MI

Tl* the contact owns a 2006 volvo xc90. The contact stated that the vehicle was leaking fuel from the fuel pump assembly. The contact stated no warning light was illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the fuel filter and fuel line needed to be replaced. The vehicle was not yet repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 244,777.

Filed Feb 16, 2021 · Fuel system · FL

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.

Filed Oct 16, 2019 · Fuel system · 188,900 miles · ID

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.