Summary
The Volvo 800 Series has 8 recalls spanning 1993 to 1998, with the most serious being a block heater defect on 1993 models where a poor fit against the engine block can allow the heater to come loose, overheat, and start a fire inside the engine compartment. A second engine-related recall affects 1994 turbocharged models: in freezing, humid conditions, ice can form in the intake system at the throttle and prevent it from returning to idle after the driver lifts off the accelerator pedal.
On the occupant safety side, 1995 models have a seatbelt catch whose threaded insert can be weak enough to pull free in a collision, leaving the belt unable to restrain the occupant. That same year, the jack supplied with certain vehicles may not support the vehicle's weight, raising the risk of the car falling while raised. The 1996 model year has a seat heater wiring defect where excessive compression of the seat cushion can damage the wiring and cause a short circuit. On 1997 models, connections inside the headlight switch can deteriorate and cause the headlights to stop working entirely.
The two lowest-severity recalls are both from 1994 and 1998. The 1994 recall covers an oxygen sensor that causes certain vehicles to exceed exhaust emissions limits. The 1998 recall involves an incorrect label on the integrated child booster cushion that states children as light as 33 pounds can use it, when the actual minimum is 40 pounds.
