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Fuel systemPart report

2004 Volvo XC90 Fuel system Problems

Complaints
77about this part
Share
17%of 462 total for the year
Median mileage
101,000miles
Trend
FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.

NHTSA recorded 77 complaints about the fuel system of the 2004 Volvo XC90, 17% of the 462 complaints for this model year. Where a mileage was given, the median is 101,000 miles. 1 recall campaign on record is filed under a similar system.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“There is a very strong smell of gas while driving at all speeds. The smell gets worse on the right hand rear passenger seat when parked. I took it in for diagnosis and was told there is a leak on top of the fuel pump. I called to Volvo of north america see if there is a recall. The lady I talked to was very nice and seamed knew exactly what I was talking about. If this a problem why is there no recall in all states in USA.”

NHTSA complaint #10923903, filed 2016-11, 114,000 miles

“Smelled gasoline, took it to a shop, they found fuel pump cracked, replaced fuel pump. Then we found out the was a recall in southern states for this problem specifically. We live in the new england area and was told it would not be considered under the recall. I feel completely wronged in this situation. The recall was specific to heat cycling. No were in the us is this more apparent than new england.”

NHTSA complaint #10662428, filed 2014-12, 109,581 miles

“Appointment set with Volvo dealer on 07/26/2010 for fuel pump recall. After the service I experienced even more stronger gasoline odor while driving. Felt nausea I had to have all windows down. Called the dealer's service department in the same day afternoon, I was told that the odor should dissipate within 2 weeks. Is it normal? How can I verify?”

NHTSA complaint #10345549, filed 2010-07, 71,779 miles

“When stationary the car will have a wet spot of fuel under the tank and when we come to a stop you can smell fuel. When I looked under the car you can see where the side of the fuel tank was wet or dripping fuel.”

NHTSA complaint #11053743, filed 2017-12, 129,000 miles

“I have had my 2004 Volvo XC90 for 2 years, no issue until 3 weeks ago started smelling fuel odor. 1 week ago, started having slow sluggish engine starts. I checked under vehicle near gas tank and noticed tank was saturated with fuel. No repairs to vehicle at this time, waiting for recall. This appears to be an issue with a large number of same year and model with issue.”

NHTSA complaint #10293572, filed 2009-11, 84,239 miles

Related recalls

Related service bulletins

Fuel system: other model years

YearComplaintsShare of year
202413%
2023615%
20221032%
2021513%
202039%
201925%
2018612%
201767%
2016137%
201319%
201115%
2010433%
2009114%
2008310%
200738%
200659%
20053315%
20047717%
20031011%

Other parts of the 2004 Volvo XC90

Electrical system
158 complaints
Transmission and drivetrain
145 complaints
Exterior lighting
32 complaints
Air bags
31 complaints
Engine
28 complaints
Engine cooling
24 complaints
Suspension
23 complaints
Steering
20 complaints
Brakes
19 complaints
Other or unknown
17 complaints
Vehicle speed control
17 complaints
Body and structure
14 complaints

← All problems reported for the 2004 Volvo XC90

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology