Summary
The Volvo XC90 has 40 recalls spanning the 2003–2025 model years, with the most serious recent issue being a software defect on 2022 plug-in hybrid models where the brakes can stop functioning entirely, raising the risk of a crash.
On the safety restraint side, 2015–2024 models have improperly torqued second-row seat belt buckle and anchor bolts that can allow the belt to detach in a crash. The 2021 model year has two related airbag control unit concerns: loose mounting screws can allow the supplemental restraint system control unit to come free in a crash, disabling airbags, seat belt pretensioners, and the high-voltage battery disconnect. That same year's passenger seat belt automatic locking retractors may fail to properly secure a child seat, though the lower anchor system remains unaffected. On 2023–2025 models, the rearview camera can fail to display when reversing, reducing visibility behind the vehicle.
The 2016–2020 XC90 Excellence models have a rear seat touch display that, when wet, can send the front passenger seat rearward and leave rear occupants unable to stop or reverse its movement. For the 2016 model year specifically, there are several restraint and airbag concerns: side impact airbag wiring in early production can be routed incorrectly and disable the front seat side airbag; third-row curtain airbags can fail to fully inflate due to a blocked D-pillar trim panel; a third-row seat belt pretensioner component can detach and become a projectile inside the cabin during deployment; and the air conditioner drain hose can leak moisture into the passenger compartment and degrade the airbag control system over time. There is also a coolant bleeder hose on 2016 models that can crack, allowing coolant to accumulate in catalytic converter insulation and ignite while the vehicle is parked. The 2016 model's sunroof switch can be pressed unintentionally and close the panel on an occupant. The 2017 model year shares the third-row seat belt pretensioner projectile risk.
The 2015 model has a separate recall for second-row seat belt buckle bolts that were not adequately tightened. The 2017–2019 model years have a connectivity module software error that can prevent the vehicle's location from being transmitted to emergency services after a crash.
The 2020 PHEV model has a high-voltage battery module that can internally short circuit and catch fire even when parked and off. Going back to the 2010–2011 model years, power steering fluid can leak at the steering gear connection, causing sudden loss of power assist. The 2010 model also has a fuel line that can leak near the right front wheel, creating a fire risk in the presence of an ignition source.
Earlier production covers several issues. The 2008 model has engine mount bolts that are too long to clamp properly, which can break the aluminum bracket and allow the engine to contact the subframe, causing stalling or loss of power. The 2007 model year has two concerns: an electric cooling fan control unit with inadequate corrosion protection that can short circuit and start an engine compartment fire, and a climate control module that can shut down after startup, leaving the driver without defrost capability in poor visibility conditions. The 2005 model has a battery maintenance design that can allow the jack crank handle to contact and short-circuit the battery, causing a fire. The 2004 model has
