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Volvo · Known Issues

2003-2025 Volvo XC90 Problems: 17 Known Issues

2003-2025 model years · 6,095+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 6,095+ owner reports, the 2003-2025 Volvo XC90 has 17 documented known issues, with 7 rated critical. The most serious are GM 4T65E Transmission Failure ($300-$6,000 repair), CEM (Central Electronic Module) Failure ($300-$1,800 repair), AEB System and Fuel Pump Recalls ($0-$0 repair), Recharge Plug-In Hybrid High-Voltage Battery / Propulsion System Faults and Reduced Performance ($0-$5,000 repair), Loss of ABS, ESC and Traction Control From Brake Control Module 2 Error (Recall 23V012000), Recall 25V179000 — XC90 Recharge T8 High-Voltage Battery Short Circuit Fire Recall and 2021 XC90 Front Seat Belt Automatic Locking Retractor Recall (21V682000). The most commonly reported issue is PCV Breather System Failure with 1,567 owner reports. Across all issues with published estimates, repair costs range from $50 to $6,000. DIY maintenance guides at au7o.io.

In This Article

  • XC90 Electrical6
  • XC90 Safety/Recalls4
  • XC90 Brakes2
  • XC90 Transmission1
  • XC90 Drivetrain1
  • XC90 Engine2
  • XC90 Suspension1
  • Recalls11
  • FAQ
Get Started
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In This Article

  • Electrical6
  • Safety/Recalls4
  • Brakes2
  • Transmission1
  • Drivetrain1
  • Engine2
  • Suspension1
  • Recalls11
  • FAQ

All 17 Known Issues

NHTSA Recalls11 recalls

BACK OVER PREVENTION:SOFTWARE

Volvo Car USA, LLC (Volvo Car) is recalling certain 2021-2025 XC40, 2022 V90, 2022-2025 S90, V90CC, C40, XC60, 2023-2025 S60, V60, V60CC, XC90, and 2025 EC40 and EX40 vehicles. The rearview camera image may not display when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Campaign #25V28200008/05/2025

BACK OVER PREVENTION:SOFTWARE

Volvo Car USA, LLC (Volvo Car) is recalling certain 2021-2025 XC40, 2022 V90, 2022-2024 C40BEV, 2022-2025 S90, V90CC, XC60, 2023-2025 S60, V60, V60CC, XC90, and 2025 EC40, and EX40 vehicles. The rearview camera image may not display when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."

Campaign #25V90800023/12/2025

ENGINE AND ENGINE COOLING:ENGINE:ENGINE CONTROL MODULE (ECU/ECM)

Volvo Car USA, LLC (Volvo Car) is recalling certain 2022-2023 S60, V60, S90L, XC60, and XC90 vehicles. An electronic control module (ECM) software error may prevent the combustion engine from starting, causing a loss of drive power.

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Frequently Asked Questions

What are the most common Volvo XC90 problems?

According to Au7o's analysis of 6,095+ owner reports, the 2003-2025 Volvo XC90 has 17 documented issues. The most frequently reported are: GM 4T65E Transmission Failure, CEM (Central Electronic Module) Failure, AEB System and Fuel Pump Recalls. Of these, 7 are rated critical and should be addressed promptly.

Is the Volvo XC90 reliable?

The 2003-2025 Volvo XC90 has 17 known issues documented across 6,095+ owner reports. 7 issues are rated critical: GM 4T65E Transmission Failure and CEM (Central Electronic Module) Failure and AEB System and Fuel Pump Recalls and Recharge Plug-In Hybrid High-Voltage Battery / Propulsion System Faults and Reduced Performance and Loss of ABS, ESC and Traction Control From Brake Control Module 2 Error (Recall 23V012000) and Recall 25V179000 — XC90 Recharge T8 High-Voltage Battery Short Circuit Fire Recall and 2021 XC90 Front Seat Belt Automatic Locking Retractor Recall (21V682000). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Volvo XC90 problems?

Repair costs for known Volvo XC90 issues range from $0 to $6,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, GM 4T65E Transmission Failure, typically costs $300-$6,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Volvo XC90 is the most reliable?

Reliability varies across model years of the Volvo XC90. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2003-2025 Volvo XC90 with 17 documented issues documented across 6,095+ owner reports.

What is the 2003-2005 Volvo XC90 GM 4T65E Transmission Failure?

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 6,095+ owner reports, NHTSA recalls, TSBs, and automotive forums.

Filter:
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When Issues Typically Appear

Recharge Plug-In Hybrid High-Voltage Battery / Propulsion System Faults and Reduced Performance
0K-50K
TCAM Telematics Module Failure Causing SOS, LTE, GPS, and App Connectivity Loss
0K-40K
Google Built-In / Center Display Freezing, Rebooting, or Losing Connectivity
0K-30K
Front Brake Squeal, Groan, and Premature Rotor/Pad Complaints
3K-30K
12V Auxiliary Battery Drain and Low-Voltage Electrical Fault Messages
5K-40K
GM 4T65E Transmission Failure
24K-36K
013K25K38K50K mi
Community reported
987 owners

The Central Electronic Module controls many vehicle functions and is prone to failure due to water intrusion from clogged A/C drain or cabin air leaks. When the CEM fails, various electrical systems malfunction including windows, locks, lights, and instrument cluster.

Common Symptoms

  • Multiple electrical malfunctions
  • Windows not working
  • Power locks inoperative
  • Instrument cluster issues
  • HVAC controls not working
  • Intermittent no-start

How to Fix

Ensure cabin air filter drain and A/C evaporator drain are clear. If CEM fails: Rebuild existing unit ($300-500) or replace with remanufactured ($500-800). The CEM must be programmed to vehicle VIN. OEM new from Volvo: $1,200-1,800. Check for water damage before buying used XC90.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • XeMODeX VO.1070.30657629.00.22 early P2 XC90 CEM program-transfer replacement service

    transfer the vehicle-specific software from a confirmed failed early CEM to a tested replacement unit Fitment/availability: 2003-2004 Volvo XC90 CEM whose installed hardware is in the listed 8645716/8645719/8688434/8688436/8688513/306576…

    XeMODeX
  • XeMODeX VO.1070.31282455.10.23 later P2 XC90 CEM program-transfer service

    transfer programming from a diagnosed failed later CEM to a customer-supplied compatible unit Fitment/availability: 2005-2013 Volvo XC90 within the supplier's 2005-2014 application whose installed CEM hardware is in the listed 30682981/3…

    XeMODeX

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $300-500 but DIY costs are typically 50-70% less
  • WarningThis is a high-severity issue - ignoring it can lead to costly repairs or safety concerns. Address it promptly.
  • TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
Typical repair cost:$300 - $1,800

Research This Issue

Based on 987 owner reports

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Community Reported
High Confidence987 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026

Volvo Car USA recalled 2020-2022 XC90 plug-in hybrid SUVs because the high-voltage battery can short circuit within a battery module while the vehicle sits parked with a fully charged pack. NHTSA files the defect under Electrical System: Software and states the consequence as an increased fire risk. For XC90 households this matters most because these SUVs are commonly charged overnight in an attached garage — and Volvo's instruction pending repair is not to charge the vehicle at all. Gasoline-only and mild-hybrid XC90s are not part of this campaign; it applies to the plug-in hybrid only. The 7,483 units NHTSA lists cover the full campaign across all included Volvo plug-in hybrid models, not the XC90 specifically.

How to Fix

Volvo dealers perform the repair at no cost: inspection of the high-voltage battery, replacement of the battery module as necessary, and a software update that monitors the battery. Do not charge the XC90 until the work is done. Check whether your VIN is included at nhtsa.gov/recalls, or contact Volvo Car customer service at 1-800-458-1552 with recall number R10312. Owner notification letters were mailed May 28, 2025.

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Community Reported
Medium ConfidenceVerifiedReviewed Aug 2026

Owners of SPA-platform Volvos including the 2023-2025 XC90 continue to report TCAM-related failures where the vehicle loses cellular service, Volvo Cars app communication, GPS position, remote start/lock functions, and sometimes emergency-call features. In many cases the issue appears as an intermittent 'SOS service required' or connectivity warning, often after software glitches or low-voltage events. The problem is well documented in owner forums and dealer service visits, with some vehicles requiring module reset, software reload, or TCAM replacement.

Common Symptoms

  • SOS service required message
  • No LTE or internet connection
  • Volvo Cars app cannot communicate with vehicle
  • Remote lock/unlock or remote start unavailable
  • GPS location incorrect or unavailable
  • Intermittent eCall/telematics warnings

How to Fix

Diagnose battery state and low-voltage history first, then scan the telematics network and verify antenna/module communication. Dealers often perform a TCAM reset, software reload, or replace the TCAM if faults return. If the vehicle also has repeated 12V battery warnings, address battery condition and charging-system behavior because undervoltage can trigger or worsen telematics faults.

Typical repair cost:$0 - $2,200

Research This Issue

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Community Reported
High Confidence

Multiple 2023-2025 XC90 owners report the Android Automotive/Google Built-In infotainment system freezing, rebooting, dropping LTE/GPS, or failing to load climate, camera, and vehicle settings menus. Unlike older Sensus complaints, this issue is specific to the newer Google-based software stack used in current XC90s. Owners commonly describe intermittent black screens, missing app tiles, inoperative backup camera display, and loss of audio/navigation until the system is reset or updated.

Common Symptoms

  • Center screen freezes or goes black
  • Infotainment reboots while driving
  • Backup camera image missing or delayed
  • Navigation/GPS unavailable
  • No LTE/data connection
  • Climate or vehicle settings inaccessible from screen
  • Apple CarPlay or Bluetooth intermittently unavailable

How to Fix

Confirm software version and check for Volvo software campaigns or over-the-air updates, as many cases are addressed by infotainment software revisions. Perform a center display reset and network reset, then scan for telematics/infotainment faults. If problems persist, dealers typically reload software, update the TCAM/infotainment modules, or replace a failed communication/display-related module if diagnostics support it.

Typical repair cost:$0 - $1,800

Research This Issue

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Community Reported
High Confidence

A recurring owner complaint on newer XC90s is unexpected 12V battery discharge leading to '12V battery critical charging fault,' no-start conditions, warning lights, and multiple electronic features going offline. The issue can be intermittent and is often tied to software sleep-state problems, telematics modules staying awake, or a weak auxiliary battery. Because the XC90 relies heavily on networked modules, low system voltage can create a cascade of unrelated warnings that disappear after charging or battery replacement.

Common Symptoms

  • 12V battery warning messages
  • No-start or hard start
  • Multiple warning lights at once
  • Remote functions stop working
  • Vehicle acts normal after jump-start or charging
  • Intermittent electrical glitches

How to Fix

Load-test the 12V battery, check charging voltage, and inspect for excessive parasitic draw after the vehicle enters sleep mode. Update vehicle software and inspect telematics/infotainment modules if the draw remains high. Replace a weak AGM battery and clear low-voltage faults; if the drain persists, dealers may need to trace module wake-up activity on the CAN network.

Typical repair cost:$250 - $1,200

Research This Issue

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Community Reported
Medium Confidence
Community reported
876 owners

The Sensus touchscreen infotainment system can experience freezing, rebooting, and unresponsive touchscreen. Climate control and many vehicle functions are controlled through this screen, making issues particularly frustrating. Software updates have improved stability.

Common Symptoms

  • Screen freezing
  • Random reboots
  • Touchscreen not responding
  • Slow response to inputs
  • Black screen
  • Apple CarPlay/Android Auto disconnecting

How to Fix

Perform a soft reset by holding the home button for 20 seconds. Check for software updates at Volvo dealer - many bugs fixed in updates. If screen unresponsive: Disconnect 12V battery for 15 minutes to reset system. For hardware failure, screen replacement runs $1,500-3,000 at dealer.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $1,500-3,000 but DIY costs are typically 50-70% less
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
  • TipSearch Volvo XC90 forums and owner groups for real-world experiences and DIY guides
  • TipGet multiple quotes from independent mechanics - dealer prices can be 2-3x higher for the same repair
Typical repair cost:$0 - $3,000

Research This Issue

Based on 876 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence876 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026
Community reported
345 owners

Multiple recalls affect 2019-2020 XC90: (1) Automatic Emergency Braking (AEB) may not function properly, (2) Fuel pump may fail causing stalling. Both are safety recalls with free repairs at Volvo dealers.

Common Symptoms

  • Recall notice received
  • AEB warning light
  • Engine stalling
  • No symptoms - hidden defects

How to Fix

Check VIN at NHTSA.gov or Volvo's recall website. Contact any Volvo dealer for free recall repairs. The AEB recall involves a software update. The fuel pump recall involves fuel pump replacement. Do not delay on safety recalls.

Owner tips & cautions

  • WarningThis is a high-severity issue - ignoring it can lead to costly repairs or safety concerns. Address it promptly.
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
  • TipSearch Volvo XC90 forums and owner groups for real-world experiences and DIY guides
  • TipGet multiple quotes from independent mechanics - dealer prices can be 2-3x higher for the same repair
  • TipCheck NHTSA.gov for active recalls — repairs are performed free at authorized dealers
Typical repair cost:$0 - $0

Research This Issue

Based on 345 owner reports

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Community Reported
High Confidence345 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026

Volvo Car USA recalled 2021 XC90 vehicles because the front seat belt automatic locking retractors may deactivate early. In a three-row family SUV this matters more than most: the seat belt is a common way to install a child restraint, especially in seating positions where lower anchors are not used. When the automatic locking retractor drops out of its locked mode prematurely, the belt can no longer secure the child restraint system properly. Volvo reported the condition to NHTSA as a non-compliance with Federal Motor Vehicle Safety Standard 208, "Occupant Crash Protection," and the recall record states plainly that an unsecured child restraint increases the risk of injury during a crash. The campaign in total covers 19,149 vehicles across all included Volvo models.

Common Symptoms

  • Seat belt does not remain locked after being fully extended to engage the child-seat locking mode
  • Child restraint installed with the seat belt does not stay tight

How to Fix

Volvo dealers will inspect the seat belt assemblies on your XC90 and replace them as necessary, free of charge. Owner notification letters were mailed October 13, 2021. Check your XC90's VIN at nhtsa.gov/recalls to see whether recall 21V682000 is still listed as open — a prior owner may or may not have had it done. Volvo Car customer service: 1-888-458-1552; the internal recall number is R10111.

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

2023-2025 XC90s are included in Volvo Car USA's rear-visibility recall. Shifting into reverse may not bring the rearview camera image up on the display. Federal Motor Vehicle Safety Standard No. 111 requires that image, so the affected XC90s fail to comply. In a vehicle this size, where the rear view is the whole point of the camera, NHTSA's stated consequence — a reduced view behind the vehicle and increased crash risk — carries real weight. Volvo identified a software cause and filed a software remedy. Note that only the 2023-2025 XC90 model years are named here; the campaign's overall 413,151-unit total covers every Volvo model in the recall, not XC90s alone.

Common Symptoms

  • Center display shows no rearview camera image after selecting reverse
  • Backup camera view fails to appear when reversing

How to Fix

The remedy is free: an updated software release, delivered either over the air or installed by a dealer. Volvo mailed owner notification letters on June 27, 2025. To confirm your specific XC90 is affected and whether the update has already been applied, enter the VIN at nhtsa.gov/recalls, or call Volvo Car customer service at 1-800-458-1552 and cite Volvo recall R10320. Until then, treat the camera as unreliable and check mirrors and blind spots before reversing.

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On 2023-2025 XC90s covered by this recall, selecting reverse may not bring up the rearview camera image on the center display. NHTSA filed the defect under back-over prevention software, and because the image can be absent when the driver shifts into R, the vehicles fail Federal Motor Vehicle Safety Standard No. 111, "Rear Visibility." In a vehicle the size of the XC90 the camera view matters, and NHTSA's stated consequence is blunt: a rearview image that does not display reduces the driver's view behind the vehicle and increases the risk of a crash. This is a software defect only — Volvo's remedy is a software update, not new camera hardware. The 413,151-vehicle figure NHTSA lists applies to the entire campaign across all included Volvo models; it says nothing about how many XC90s are involved. Note also that 25V908000 replaces the earlier recall 25V282.

Common Symptoms

  • No camera image on the center display after shifting into reverse
  • Blank or unchanged screen where the reverse view should be

How to Fix

Free of charge at a Volvo dealer, or delivered over-the-air if your XC90 is set up to receive OTA updates: the affected software is updated so that the rearview camera image displays reliably when reverse is engaged. Volvo mailed owner letters on February 24, 2026, and VINs went live in NHTSA's lookup on February 16, 2026 — check yours at nhtsa.gov/recalls before booking anything, since an OTA update may already have closed it out. Questions go to Volvo Car customer service at 1-800-458-1552, recall reference R10333. XC90s repaired under the superseded recall 25V282 are not finished; they still need this remedy.

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

Volvo Car USA recalled certain 2023 XC90 vehicles under NHTSA campaign 23V012000. The cause is a diagnostic error in the Brake Control Module 2 (BCM2) that may lead to a loss of the Antilock Brake System, Electronic Stability Control and traction control. The XC90 is a tall, heavy three-row SUV, and stability control does real work on it during emergency lane changes and slippery-surface manoeuvres, so losing that layer of brake support is the safety issue NHTSA identifies as increasing crash risk. The defect sits in the module's software rather than in the hydraulic hardware. NHTSA's 27,457-unit count applies to the entire campaign, which includes several other 2023 Volvo models alongside the XC90. Volvo's own recall number is R10217.

Common Symptoms

  • ABS unavailable
  • Electronic Stability Control not operating
  • Traction control loss
  • Brake support functions reduced

How to Fix

The remedy is free: an updated BCM2 software release distributed over the air. XC90s that are connected and set to receive updates may already have it; if not, any Volvo dealer will install the update at no cost. Volvo began mailing owner notification letters March 15, 2023. To verify whether your XC90 still needs it, check the VIN at nhtsa.gov/recalls or contact Volvo Car customer service at 1-800-458-1552 referencing R10217.

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

Owners of recent XC90s frequently report persistent front brake squeal or groaning at low speeds, sometimes accompanied by pulsation or early rotor replacement recommendations. The issue appears on both mild-hybrid and Recharge variants and is often most noticeable during light braking after the vehicle has sat overnight or in damp conditions. In some cases dealers resurface or replace pads/rotors, but noise can return if the underlying pad compound or rotor condition is unchanged.

Common Symptoms

  • Front brake squeal at low speed
  • Groaning noise when stopping
  • Brake pulsation
  • Noise worse in damp or cold weather
  • Premature front pad or rotor wear

How to Fix

Inspect rotor runout, pad wear pattern, and caliper slide movement, and verify whether Volvo has updated pad or hardware guidance for the specific VIN. If noise is severe or pulsation is present, replace pads and rotors as a set and clean/lubricate contact points with the correct brake lubricant. A proper bed-in procedure after replacement can reduce repeat noise complaints.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Brembo 31471752KT6 345 mm front brake kit

    replace worn, contaminated, glazed, out-of-spec or damaged front pads and rotors as a matched axle set on the 345 mm branch Fitment/availability: 2023-2025 Volvo XC90 whose VIN, brake code, caliper and measured front rotor confirm the 34…

    FCP Euro
  • Textar 31400569KT2 366 mm front brake kit

    replace failed front pads and rotors as a matched axle set on the confirmed 366 mm branch Fitment/availability: 2023-2025 Volvo XC90 whose VIN, brake code, caliper and measured front rotor confirm the 366 mm/19-inch package; excludes the…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$400 - $1,400

Research This Issue

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Community Reported
Medium Confidence
Community reported
1,234 owners

The 2003-2005 XC90 with the T6 engine uses a GM 4T65E transmission that is prone to failure. The transmission was designed for lower-torque applications and struggles with the T6's power. Overheating and internal component failure are common.

Common Symptoms

  • Harsh shifting
  • Transmission slipping
  • Delayed engagement
  • Overheating warning
  • Shudder during acceleration
  • Complete transmission failure

How to Fix

Change transmission fluid and filter every 30,000 miles using Volvo OEM fluid only. Install an auxiliary transmission cooler ($150-300) to reduce operating temperature. If transmission fails, consider a rebuilt unit with upgraded internals ($2,500-4,000) or swap to a 6-speed Aisin unit from later XC90s ($4,000-6,000).

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Liqui Moly 271697KT 4T65EV/GT transmission service kit

    service a diagnosably serviceable transmission with the correct fluid, pan filter and seal after contamination and failure assessment Fitment/availability: 2003-2005 Volvo XC90 T6 B6294T with confirmed GM 4T65EV/GT transmission; includes…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $150-300 but DIY costs are typically 50-70% less
  • WarningThis is a high-severity issue - ignoring it can lead to costly repairs or safety concerns. Address it promptly.
  • TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
Typical repair cost:$300 - $6,000

Research This Issue

Based on 1,234 owner reports

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Community Reported
High Confidence1,234 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026

XC90 Recharge owners have reported propulsion-system warnings, inability to charge, reduced power, and 'hybrid system failure' type messages affecting drivability. On some vehicles the fault triggers a check-engine light, limited EV operation, or a transition to reduced-performance mode. These complaints appear across owner forums and NHTSA filings for recent Recharge models and can involve battery management, onboard charging, cooling, or high-voltage isolation faults.

Common Symptoms

  • Propulsion system service required
  • Reduced engine performance
  • Vehicle will not charge
  • Check engine light with hybrid warnings
  • EV mode unavailable
  • Vehicle enters limp mode

How to Fix

Scan the hybrid control modules with Volvo-capable diagnostics and inspect freeze-frame data for battery, charger, and isolation-related faults. Dealers typically update hybrid control software first, then test the onboard charger, battery coolant circuits, contactors, and high-voltage battery components. Because of the safety and warranty implications, high-voltage diagnosis should be handled by a Volvo retailer or qualified hybrid specialist.

Typical repair cost:$0 - $5,000

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Community Reported
Medium Confidence
Community reported
1,567 owners

The Positive Crankcase Ventilation (PCV) system includes a breather box and hoses that degrade over time. When the PCV fails, it causes oil leaks, rough idle, and can blow out gaskets due to excessive crankcase pressure. This is a common issue on 5-cylinder Volvos.

Common Symptoms

  • Oil leaks from various gaskets
  • Rough idle
  • Whistling noise from engine
  • Check engine light
  • Oil consumption increase
  • White smoke from exhaust

How to Fix

Replace the entire PCV breather box assembly along with associated hoses ($150-300 in parts). This is a common maintenance item - include it with timing belt service. DIY takes 2-4 hours. Also replace flame trap if equipped. Use OEM or quality aftermarket parts.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Volvo 8692211KT B5254T2 PCV breather-system kit

    replace a pressure-tested restricted or failed five-cylinder breather box and associated hoses as a matched system Fitment/availability: 2003-2007 Volvo XC90 2.5T B5254T2 branch using oil trap 8692211 and the included coolant-pipe config…

    FCP Euro
  • Genuine Volvo 31319642 B6324S PCV valve-cover oil separator

    replace a diagnosed failed SI6 oil-separator/PCV assembly with the correct gasketed unit Fitment/availability: 2007-2014 Volvo XC90 3.2 B6324S/B6324S5 branch whose VIN and installed top-mounted separator confirm 31319642; excludes 2.5T f…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $150-300 but DIY costs are typically 50-70% less
  • TipThis is a common maintenance item - include it with timing belt service.
  • TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
Typical repair cost:$150 - $600

Research This Issue

Based on 1,567 owner reports

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Community Reported
High Confidence1,567 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026
Community reported
654 owners

Early 2nd generation XC90s with the T6 engine may consume excessive oil between changes. Some owners report needing to add a quart every 1,500-3,000 miles. Volvo updated piston rings in later production.

Common Symptoms

  • Low oil warning between changes
  • Need to add oil frequently
  • Blue smoke on startup
  • Oil smell from exhaust

How to Fix

Check oil level every 1,000 miles and top up as needed. Use Volvo-approved 0W-20 synthetic oil only. If consumption exceeds 1 quart per 1,000 miles, document with dealer for possible warranty claim. Piston ring replacement if out of warranty: $3,000-6,000. Later production engines (late 2017+) have updated rings.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Castrol Edge 32140029KT6 VCC RBS0-2AE 0W-20 oil-change kit

    supply the specified oil and filter for maintenance or measured top-up while the consumption cause is documented and repaired Fitment/availability: 2016-2017 Volvo XC90 T6 B4204T27 using VCC RBS0-2AE 0W-20, Hengst filter and drain seal; …

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $3,000-6,000 but DIY costs are typically 50-70% less
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
Typical repair cost:$50 - $6,000

Research This Issue

Based on 654 owner reports

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Community Reported
Medium Confidence654 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026
Community reported
432 owners

The optional rear air suspension on 2nd gen XC90s can develop leaks in the air springs or compressor failure. The system is used for automatic load leveling and ride height adjustment. Air springs develop cracks over time.

Common Symptoms

  • Rear sagging overnight
  • Compressor running constantly
  • Suspension fault message
  • Rough ride in rear
  • Vehicle leaning to one side

How to Fix

For air spring leaks: Replace individual air springs ($300-500 each). For compressor failure: Replace compressor ($500-1,000). Convert to conventional springs and bypass air system ($400-800) if prefer maintenance-free setup. OEM repair at dealer: $1,500-3,500 depending on components failed.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Arnott 32246194KT pair of rear air springs

    replace pressure-tested leaking or cracked rear air springs as an axle pair Fitment/availability: 2016-2019 Volvo XC90 equipped from the factory with self-leveling air suspension and whose VIN/original rear spring numbers cross to 322461…

    FCP Euro
  • Genuine Volvo 32315091 air-suspension compressor

    replace a compressor that fails current, pressure, output or internal-fault testing after all system leaks and control faults are corrected Fitment/availability: SPA Volvo XC90 factory auto-leveling air-suspension system using current co…

    FCP Euro

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipDIY repairs can save significantly - dealer charges $300-500 but DIY costs are typically 50-70% less
  • TipConvert to conventional springs and bypass air system ($400-800) if prefer maintenance-free setup.
  • TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
  • TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
Typical repair cost:$400 - $3,500

Research This Issue

Based on 432 owner reports

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Community Reported
Medium Confidence432 owner reportsLast reported by owners Feb 2024Reviewed Feb 2026
Campaign #22V79300020/10/2022

SEAT BELTS:CRITICAL FASTENERS

Volvo Car USA, LLC (Volvo Car) is recalling certain 2015-2024 XC90 vehicles. The second-row seat belt buckle and lower belt anchor bolts may not be tightened properly.

Campaign #23V82700007/12/2023

STEERING

Volvo Car USA, LLC (Volvo Car) is recalling certain 2019-2022 V60CC, XC60, and XC90 vehicles. During steering gear assembly, double screws may have been assembled on top of each other, which can cause a screw to fall into the gearbox housing.

Campaign #23V00100005/01/2023

+ 6 more recalls. Check all on NHTSA.gov

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

get a full repair guide

The 2003-2005 XC90 with the T6 engine uses a GM 4T65E transmission that is prone to failure. The transmission was designed for lower-torque applications and struggles with the T6's power. Overheating and internal component failure are common. Repairs typically run $300-$6,000. Severity: high.

What is the 2003-2013 Volvo XC90 CEM (Central Electronic Module) Failure?

The Central Electronic Module controls many vehicle functions and is prone to failure due to water intrusion from clogged A/C drain or cabin air leaks. When the CEM fails, various electrical systems malfunction including windows, locks, lights, and instrument cluster. Repairs typically run $300-$1,800. Severity: high.

What is the 2019-2020 Volvo XC90 AEB System and Fuel Pump Recalls?

Multiple recalls affect 2019-2020 XC90: (1) Automatic Emergency Braking (AEB) may not function properly, (2) Fuel pump may fail causing stalling. Both are safety recalls with free repairs at Volvo dealers. Repairs typically run $0-$0. Severity: high.

What is the 2023-2025 Volvo XC90 Recharge Plug-In Hybrid High-Voltage Battery / Propulsion System Faults and Reduced Performance?

XC90 Recharge owners have reported propulsion-system warnings, inability to charge, reduced power, and 'hybrid system failure' type messages affecting drivability. On some vehicles the fault triggers a check-engine light, limited EV operation, or a transition to reduced-performan… Repairs typically run $0-$5,000. Severity: high.

What is the 2023 Volvo XC90 Loss of ABS, ESC and Traction Control From Brake Control Module 2 Error (Recall 23V012000)?

Volvo Car USA recalled certain 2023 XC90 vehicles under NHTSA campaign 23V012000. The cause is a diagnostic error in the Brake Control Module 2 (BCM2) that may lead to a loss of the Antilock Brake System, Electronic Stability Control and traction control. The XC90 is a tall, heav… Severity: high.

What is the 2020-2022 Volvo XC90 Recall 25V179000 — XC90 Recharge T8 High-Voltage Battery Short Circuit Fire Recall?

Volvo Car USA recalled 2020-2022 XC90 plug-in hybrid SUVs because the high-voltage battery can short circuit within a battery module while the vehicle sits parked with a fully charged pack. NHTSA files the defect under Electrical System: Software and states the consequence as an… Severity: high.

What is the 2021 Volvo XC90 2021 XC90 Front Seat Belt Automatic Locking Retractor Recall (21V682000)?

Volvo Car USA recalled 2021 XC90 vehicles because the front seat belt automatic locking retractors may deactivate early. In a three-row family SUV this matters more than most: the seat belt is a common way to install a child restraint, especially in seating positions where lower… Severity: high.

What is the 2003-2014 Volvo XC90 PCV Breather System Failure?

The Positive Crankcase Ventilation (PCV) system includes a breather box and hoses that degrade over time. When the PCV fails, it causes oil leaks, rough idle, and can blow out gaskets due to excessive crankcase pressure. This is a common issue on 5-cylinder Volvos. Repairs typically run $150-$600. Severity: medium.

What is the 2015-2017 Volvo XC90 Excessive Oil Consumption?

Early 2nd generation XC90s with the T6 engine may consume excessive oil between changes. Some owners report needing to add a quart every 1,500-3,000 miles. Volvo updated piston rings in later production. Repairs typically run $50-$6,000. Severity: medium.

What is the 2016-2019 Volvo XC90 Rear Air Suspension Failure?

The optional rear air suspension on 2nd gen XC90s can develop leaks in the air springs or compressor failure. The system is used for automatic load leveling and ride height adjustment. Air springs develop cracks over time. Repairs typically run $400-$3,500. Severity: medium.

What is the 2023-2025 Volvo XC90 TCAM Telematics Module Failure Causing SOS, LTE, GPS, and App Connectivity Loss?

Owners of SPA-platform Volvos including the 2023-2025 XC90 continue to report TCAM-related failures where the vehicle loses cellular service, Volvo Cars app communication, GPS position, remote start/lock functions, and sometimes emergency-call features. In many cases the issue ap… Repairs typically run $0-$2,200. Severity: medium.

What is the 2023-2025 Volvo XC90 Google Built-In / Center Display Freezing, Rebooting, or Losing Connectivity?

Multiple 2023-2025 XC90 owners report the Android Automotive/Google Built-In infotainment system freezing, rebooting, dropping LTE/GPS, or failing to load climate, camera, and vehicle settings menus. Unlike older Sensus complaints, this issue is specific to the newer Google-based… Repairs typically run $0-$1,800. Severity: medium.

What is the 2023-2025 Volvo XC90 12V Auxiliary Battery Drain and Low-Voltage Electrical Fault Messages?

A recurring owner complaint on newer XC90s is unexpected 12V battery discharge leading to '12V battery critical charging fault,' no-start conditions, warning lights, and multiple electronic features going offline. The issue can be intermittent and is often tied to software sleep-… Repairs typically run $250-$1,200. Severity: medium.

What is the 2023-2025 Volvo XC90 XC90 Rearview Camera Blank on Reverse — Software Recall 25V282000?

2023-2025 XC90s are included in Volvo Car USA's rear-visibility recall. Shifting into reverse may not bring the rearview camera image up on the display. Federal Motor Vehicle Safety Standard No. 111 requires that image, so the affected XC90s fail to comply. In a vehicle this size… Severity: medium.

What is the 2023-2025 Volvo XC90 Reverse Camera View May Not Appear on the Center Screen (Recall 25V908000)?

On 2023-2025 XC90s covered by this recall, selecting reverse may not bring up the rearview camera image on the center display. NHTSA filed the defect under back-over prevention software, and because the image can be absent when the driver shifts into R, the vehicles fail Federal… Severity: medium.

What is the 2023-2025 Volvo XC90 Front Brake Squeal, Groan, and Premature Rotor/Pad Complaints?

Owners of recent XC90s frequently report persistent front brake squeal or groaning at low speeds, sometimes accompanied by pulsation or early rotor replacement recommendations. The issue appears on both mild-hybrid and Recharge variants and is often most noticeable during light b… Repairs typically run $400-$1,400. Severity: medium.

What is the 2016-2022 Volvo XC90 Sensus Infotainment System Issues?

The Sensus touchscreen infotainment system can experience freezing, rebooting, and unresponsive touchscreen. Climate control and many vehicle functions are controlled through this screen, making issues particularly frustrating. Software updates have improved stability. Repairs typically run $0-$3,000. Severity: low.