Table 1 shows one common other fuel system related problems of the 2020 Volvo XC90.
| Problem Category | Number of Problems |
|---|---|
| Other Fuel System problems |
Supplemental to NHTSA complaint #11713668. This is a supplemental filing regarding the 2020 Volvo Xc90 t8 inscription, VIN [xxx] . The hybrid battery cell module failed in December 2025, disabling the vehicle's hybrid propulsion system, all-wheel drive, and electric-only mode. As of this filing, the vehicle has been without hybrid functionality for over four months. The replacement part remains unavailable. Since the original complaint, the owner initiated civil proceedings against Volvo car USA llc and Volvo car north America llc in the state court of gwinnett county, georgia (case no. [xxx]). Through that litigation, the following facts have been established as deemed admissions under georgia law, which neither defendant contested: 1. This vehicle is excluded from recall 25v-179, yet experienced a catastrophic hybrid battery cell module failure. 2. Battery failures in 2019-2022 Xc90 t8 vehicles are not exclusively caused by the "lg supplier process deviation" identified in recall 25v-179. 3. Volvo is aware of battery failures in 2019-2022 Xc90 t8 vehicles outside the recall 25v-179 population. 4. Volvo possesses internal engineering data showing the battery defect affects vehicles outside the population reported to NHTSA in recall 25v-179. 5. Volvo has not issued a recall for the specific failure mode affecting this vehicle. 6. Expanding recall 25v-179 to cover the full 2019-2022 Xc90 t8 population would cost Volvo tens of millions of dollars. These facts were established against both Volvo entities through separate sets of requests for admission that went unanswered within the statutory deadline. The owner requests that NHTSA evaluate whether recall 25v-179 is adequate to protect the full population of affected vehicles. Supporting documentation, including copies of the deemed admissions and service records, is being submitted by mail to the office of defect investigation. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).
In early December (2025), I experienced hybrid system failure, with the vehicle showing this fault in the dashboard and the check engine light coming on. I took it to the dealership, as the hybrid system is still within warranty, and they diagnosed a failed hybrid battery module. They said I could continue to drive the care in combustion-only mode and would order the module. Having heard nothing, I checked in early January and was told the module would not be available until may or June of 2026. I escalated to Volvo corporate. They opened a case and keep promising to have a manager reach out to update me, but they have failed to follow-through for almost a month. I am now faced with the prospect of operating an impaired vehicle that can't pass an emissions test (and which is under warranty) for more than half a year.
I was driving the speed limit on the highway in my Volvo 2020 Xc90 which was less than one year old. The vehicle lost acceleration power and then an engine performance light came on, then a check engine light. I pulled over immediately and my car engine caught fire under the hood. The entire front of vehicle was engulfed in flames within minutes. There were approximately 11k miles on the car and it had never been maintenanced or worked on in any way that would have caused an engine fire. It was clearly a fuel line fire and Volvo did not properly investigate. My insurance company said it was a fuel line fire but could not get information from the black box because it was destroyed. This car is incredibly unsafe and should be recalled. I have multiple videos and case files concerning this "thermal event". Volvo recalled this car in europe because of this issue and says there are none in the USA.