Fuel pump failure on the 2004 Volvo Xc90
1 injury 1 of the 57 reports for this failure mention a crash, a fire, an injury or a death. Those are the owner's words on the complaint form, not a verified finding, and one report can mention more than one.
When fuel pump failure gets reported
Owners of the 2004 Volvo Xc90 report fuel pump failure at a median of 80,000 miles. A quarter of the reports come in before 52,500 miles and a quarter after 130,000 miles, from 42 reports that carried an odometer reading.
A part like this is normally expected to survive 85,000 miles. It is the 4th most-reported problem on this model year.
The mileage distribution
The reported range runs from 32,500 miles at the tenth percentile to 162,500 miles at the ninetieth, a spread of 131,100 miles across the middle 80% of reports.
A spread this wide points at use rather than design. Towing, climate, service history and city mileage all move a failure like this, so the median is a weak guide to any individual car.
17% of the dated reports were filed under 36,000 miles.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| 32,400 miles | 52,250 miles | 80,802 miles | 130,000 miles | 163,500 miles |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Of these reports, 1 an injury is mentioned. Owners write their own complaints and the agency does not verify them, so read this as what the reports say happened rather than as a confirmed count.
Putting it right typically runs $600–$2,600 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 5 model years of this car. It shows up earliest on the 2016, at a median of 30,000 miles, and latest on the 2006 at 190,000 miles.
By volume the 2004 is the worst of them, which makes this a problem of this specific year rather than of the model as a whole.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
While the car was parked in the garage there was an overwhelming smell of gasoline. I took the car to my mechanic. They observed a fuel leak coming from fuel pump housing. A new fuel pump was installed. *tr
In march of 2008 I noticed a strong odor of gasoline in the garage were the vehicle was stored. This odor had also permeated through out the interior of the vehicle. Checked vehicle for fuel leaks and could not determine source due to quick evaporation of fuel. On march 17, 08 local dealer found leak at top of fuel tank under 2nd row seats. Replaced fuel pump and "faulty" level sensor. On march 27, 08 I returned vehicle to dealer with same problem. They tried to pacify me by saying it was residual odor and would go away with time. After inspection by dealer, it was still leaking. Solution per documentation was to replace level sensor o-ring on left side. However the tech informed me the fuel tank with pump and sending unit were all replaced. On september 16, 08 I am having the same problem again. It is back to dealer, stay tuned...... *tr
Fuel pump leaking causing internal gas fumes with passenger hazard and visible leaking of gasoline onto road from the pump-gas tank assembly. The fuel pump was on a warranty from state of california. However when dealer replaced fuel pump kit the pump-assembly continues to leak. Car is a 2004 xc-90 volvo with 60k miles. *tr
Also reported on the 2004 Volvo Xc90
Other electrical problem
Other powertrain problem
Complete transmission failure
Loss of braking
Other engine problem
Other fuel system problem
How far this goes
Complaints are voluntary, so 57 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does fuel pump failure happen on the 2004 Volvo Xc90?
Across 42 owner reports that included an odometer reading, half were filed by 80,000 miles. A quarter were filed before 52,500 miles and a quarter after 130,000 miles. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is fuel pump failure on the 2004 Volvo Xc90?
57 reports have been filed with NHTSA, about 1.8 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed