2016 Volvo XC90 problems

ENGINE

I discovered an engine coolant leak from a crack near the end of the Plastic Coolant Bypass Pipe (part #31368673/32382362) after noticing coolant puddling on my garage floor. There are numerous comments with pictures on-line about how common this part fails on this model Volvo. What's also interesting is that the "pipe" fails in exactly the same location (on top and near the end). Seems to me if this is a known defect and the part is not performing with reasonable reliability, Volvo should provide an allowance to car owners when the part fails.

NHTSA complaint #11757537 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

Piston rings inside the engine failed due to a known oil consumption issue with this model vehicle. The engine failed while the car was driving 85 mph and consequently slowed down to 15mph on the highway, leaving the owner of the car stranded alone on the highway. Volvo has a known fix for this issue and there was a class action lawsuit for it, but since it was settled, there was no recall. This is, in fact, a dangerous issue that is preventable. Additionally, the sunroof drains also leak. Water frequently leaks down the A-pillar directly onto the Central Electronic Module (CEM) causing unsafe electrical issues and potential engine failure. This was a known issue on other models, but it is also present in this model vehicle. When I tried to fix this under a warranty contract, I was denied by the certified repair shops.

NHTSA complaint #11751100 — an unverified report by a vehicle owner.

ENGINE

Piston rings inside the engine failed due to a known oil consumption issue with this model vehicle. The engine failed while the car was driving 85 mph and consequently slowed down to 15mph on the highway, leaving the owner of the car stranded alone on the highway. Volvo has a known fix for this issue and there was a class action lawsuit for it, but since it was settled, there was no recall. This is, in fact, a dangerous issue that is preventable. Additionally, the sunroof drains also leak. Water frequently leaks down the A-pillar directly onto the Central Electronic Module (CEM) causing unsafe electrical issues and potential engine failure. This was a known issue on other models, but it is also present in this model vehicle. When I tried to fix this under a warranty contract, I was denied by the certified repair shops.

NHTSA complaint #11751100 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

The AC evaporator has a leak. I am reporting as this is a well known issue on the Volvo's, especially the 2016 XC90 which has a large amount of issues that cause issues of safety and undue amount of financial burden on owners who operate the vehicle in normal conditions. I have been told by the dealer after they repaired a another issue of the engine (8 times this vehcile has been in for repair on engine issues that are due to a block issue) the ac evaporator is well known by Volvo to be poorly designed and manufatcurered where they last under ten years. I have asked dealers and mechainc shops who see dozens a week of these repairs needed. The avergae cost I have been quote is $4000 for repair and the volvo service dealer I could told me, these keep the shop going. There is no way that this is not a issue to the public that puts a undue burden to owners, one that Volvo HQ in USA acknowledges is a issue but is not required to do anything.

NHTSA complaint #11749074 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

My 2016 Volvo XC90 suddenly lost power while I was driving, requiring me to pull over and have the vehicle towed. This is a documented safety issue associated with a known piston ring defect in 2013-2016 Volvo vehicles equipped with 2.0L and 2.5L engines, which was the subject of a federal class action lawsuit ([XXX] et al. v. Volvo Car USA, LLC, Case No. XXX, filed XXX. No there we NO warning lamps, messages or other symptoms of the problem prior to the failure. I purchased this vehicle as a second owner from Carvana [XXX] — one month after the class action was filed. I was never notified of the defect, the litigation, or any service campaign or extended warranty coverage associated with this VIN, through Carvana nor Volvo. Since the power loss, I have spent $11,543.75 in out-of-pocket repairs (replacement engine, labor, towing). Despite a new engine being installed, the vehicle enters limp mode within one mile of driving. A Volvo-authorized dealer has quoted an additional $19,959.65 in repairs without certifying that the work will resolve the safety issue. Volvo Customer Care has declined to assist, stating their internal service campaign has concluded. I am submitting this safety complaint because sudden, unexplained power loss in a moving vehicle is a significant safety hazard, and because second owners of affected vehicles were never properly notified of the defect. I never knew nor was this disclosed to me before purchase from Carvana nor told to me by Volvo. I was in the middle of nowhere and I was not sure what to do and being a single woman, I was unsafe and scared. What ever this issue is Volvo and the dealer in South Dakota (where it is parked right now) as I had it towed on June 5th, and they don't want to help nor fix my vehicle. I need my catering business vehicle as this is a very concerning for my loss of use for over a year now for my catering part of my business. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11746768 — an unverified report by a vehicle owner.

ENGINE

My 2016 Volvo XC90 suddenly lost power while I was driving, requiring me to pull over and have the vehicle towed. This is a documented safety issue associated with a known piston ring defect in 2013-2016 Volvo vehicles equipped with 2.0L and 2.5L engines, which was the subject of a federal class action lawsuit ([XXX] et al. v. Volvo Car USA, LLC, Case No. XXX, filed XXX. No there we NO warning lamps, messages or other symptoms of the problem prior to the failure. I purchased this vehicle as a second owner from Carvana [XXX] — one month after the class action was filed. I was never notified of the defect, the litigation, or any service campaign or extended warranty coverage associated with this VIN, through Carvana nor Volvo. Since the power loss, I have spent $11,543.75 in out-of-pocket repairs (replacement engine, labor, towing). Despite a new engine being installed, the vehicle enters limp mode within one mile of driving. A Volvo-authorized dealer has quoted an additional $19,959.65 in repairs without certifying that the work will resolve the safety issue. Volvo Customer Care has declined to assist, stating their internal service campaign has concluded. I am submitting this safety complaint because sudden, unexplained power loss in a moving vehicle is a significant safety hazard, and because second owners of affected vehicles were never properly notified of the defect. I never knew nor was this disclosed to me before purchase from Carvana nor told to me by Volvo. I was in the middle of nowhere and I was not sure what to do and being a single woman, I was unsafe and scared. What ever this issue is Volvo and the dealer in South Dakota (where it is parked right now) as I had it towed on June 5th, and they don't want to help nor fix my vehicle. I need my catering business vehicle as this is a very concerning for my loss of use for over a year now for my catering part of my business. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11746768 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

My 2016 Volvo XC90 suddenly lost power while I was driving, requiring me to pull over and have the vehicle towed. This is a documented safety issue associated with a known piston ring defect in 2013-2016 Volvo vehicles equipped with 2.0L and 2.5L engines, which was the subject of a federal class action lawsuit ([XXX] et al. v. Volvo Car USA, LLC, Case No. XXX, filed XXX. No there we NO warning lamps, messages or other symptoms of the problem prior to the failure. I purchased this vehicle as a second owner from Carvana [XXX] — one month after the class action was filed. I was never notified of the defect, the litigation, or any service campaign or extended warranty coverage associated with this VIN, through Carvana nor Volvo. Since the power loss, I have spent $11,543.75 in out-of-pocket repairs (replacement engine, labor, towing). Despite a new engine being installed, the vehicle enters limp mode within one mile of driving. A Volvo-authorized dealer has quoted an additional $19,959.65 in repairs without certifying that the work will resolve the safety issue. Volvo Customer Care has declined to assist, stating their internal service campaign has concluded. I am submitting this safety complaint because sudden, unexplained power loss in a moving vehicle is a significant safety hazard, and because second owners of affected vehicles were never properly notified of the defect. I never knew nor was this disclosed to me before purchase from Carvana nor told to me by Volvo. I was in the middle of nowhere and I was not sure what to do and being a single woman, I was unsafe and scared. What ever this issue is Volvo and the dealer in South Dakota (where it is parked right now) as I had it towed on June 5th, and they don't want to help nor fix my vehicle. I need my catering business vehicle as this is a very concerning for my loss of use for over a year now for my catering part of my business. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11746768 — an unverified report by a vehicle owner.

POWER TRAIN

The eRAD (Electric Rear Axle Drive) on my 2016 Volvo XC90 T8 PHEV failed completely. The warning light appeared approximately 11/3/2025, within one week of purchasing the vehicle at 88,000 miles. The failure was confirmed by a Volvo dealership. The eRAD is the component that powers the rear electric motor and provides AWD and hybrid function — its failure results in complete loss of rear wheel drive and hybrid system operation. Safety risk includes unexpected loss of AWD traction control in adverse weather conditions. This is a known systemic defect acknowledged in Volvo’s own Technical Journals (TJ33358). I contacted Volvo Cars USA customer service to invoke the SULEV emissions warranty and they were unable to locate my claim or explain the warranty coverage. Volvo has not addressed this through a recall despite this being a widespread known failure mode affecting XC90 T8 models. The vehicle is available for inspection.

NHTSA complaint #11737317 — an unverified report by a vehicle owner.

ENGINE

Vehicle start shaking Violently out of control. AAA picked up the vehicle and took it to their European shop and discovered it’s the piston rings . I asked Volvo to do a goodwill repair and they rejected my claim on a well know issue that I was not brought aware while having the vehicle serviced at their facility Findley Volvo dealership. I’ve been taking this vehicle there for two years, with an oil problem. They never did an oil consumption test or correct the piston issue. I am appalled at this action and behavior by the dealership.A well documented issue with this vehicle. They told the program has expired, I’d have to pay for service . I have photos as well of the issue.

NHTSA complaint #11734718 — an unverified report by a vehicle owner.

ENGINE

Since moving here to Nevada in 2023, I’ve had several oil changes. After about 1200 I have to add mother oil to the car. I’ve gone back three times to 5 min oil change to get free refills since they offer free top offs after your initial oil change. I than took a deep dive on the internet and discovered that the Volvo XC90, 2016 had issues with oil consumption, but never informed me of this issue. I’ve been to the dealership several times and not once did the inform me either. I mentioned to Bailey Anderson at Findlay Volvo in Las Vegas that this car consumes a lot of oil. He said no it didn’t without even checking for facts. I read that Volvo knew about this issue and we’re fixing the issue, however when I inquired they wanted me to pay for their mistake. How is that so when they knew there is and was an oil consumption matter and did not inform me of the matter. I’m furious with Volvo for hiding or concealing this issue. How can I get them to correct the matter, at this point?

NHTSA complaint #11732842 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Since moving here to Nevada in 2023, I’ve had several oil changes. After about 1200 I have to add mother oil to the car. I’ve gone back three times to 5 min oil change to get free refills since they offer free top offs after your initial oil change. I than took a deep dive on the internet and discovered that the Volvo XC90, 2016 had issues with oil consumption, but never informed me of this issue. I’ve been to the dealership several times and not once did the inform me either. I mentioned to Bailey Anderson at Findlay Volvo in Las Vegas that this car consumes a lot of oil. He said no it didn’t without even checking for facts. I read that Volvo knew about this issue and we’re fixing the issue, however when I inquired they wanted me to pay for their mistake. How is that so when they knew there is and was an oil consumption matter and did not inform me of the matter. I’m furious with Volvo for hiding or concealing this issue. How can I get them to correct the matter, at this point?

NHTSA complaint #11732842 — an unverified report by a vehicle owner.

ENGINE

Hey I purchased a Volvo xc90 2016 seven months ago and I currently still have this car. Also others with the same model, are having problems with oil consumption who is the problem that I’m sadly dealing with, My car burns so much oil and I’m only 19 I got this hoping for a reliable car but in stead in burns oil just has much as I burn fuel every 500 miles, if that probably less miles. it tells me to had a liter of oil because it says I’m out of oil. I just need some one to help me it hasn’t had anything done to it it’s all original with only 127,000 miles on it and this probably has been happening since I purchased it with only 118,000 miles.

NHTSA complaint #11731647 — an unverified report by a vehicle owner.

ENGINE

*the engine is the part that failed due to excessive oil consumption. *it became a safety risk once it started selecting its own driving speed after dropping driving speed to 31mph on [XXX in Raleigh. *the problem was confirmed by the dealer, Volvo of Cary *it has not been inspected by the manufacturer, police, insurance representatives or others *upon a service visit our technician, Ray Rancell of Volvo of Cary advised that the engine was leaking oil and engine failure would occur if we didn't take care of it so we did to a total of $2879.74 which would keep the engine from seizing. That means we paid to prevent exactly what happened anyway and as I found out later he did not perform an oil consumption test so he had no way of knowing the shape the engine was in but charged for this work anyway. The repair invoice says the customer stated oil leaking on timing belt but that is incorrect. I would have no way of knowing that as the only thing i know about cars is replinishg fluids. We did have to replinish oil often and advised Ray of that but he said it was normal. Thank God I was able to get into the slow lane and prevented any accident but my and my daughter's life was certainly put at risk. There is a known recall for excessive oil consumption which I fould out about later. When I questioned Volvo they said my VIN number was not included in the recall. Clearly, it should have been. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11712975 — an unverified report by a vehicle owner.

ENGINE

My vehicle was signaling me to add oil every 600 - 1000 miles around 85,000 miles. The dealership charged me for a chemical treatment to stop the oil burning around 90,000 miles. At about 95,000 miles, my engine failed while driving on the interstate. There was no warning light or degradation of power. Suddenly, the engine lost power, went into limp mode and I could not maintain highway speed. The display flashes "Engine Performance Reduced." My SUV is now parked in my yard. I have paid two Volvo dealerships and a Volvo repair shop to inspect it. They reported oil burning, cylinder scoring and spark plug failure. There is scoring in the #3 cylinder and there is also no compression in the #3 cylinder. They further advised me that ALL engines that fit in my vehicle will experience this oil burning issue and the subsequent pathway to failure. I see evidence that this is a known issue with 2.0L and 2.5L Volvo engines between 2013-16. Of particular note is that several other owners have experienced failure in the #3 cylinder. There is an issue of clogged rings causing oil burning. Oil burning leads to damage to internal engine components like pistons, spark plugs, valves and etc..causing engine failure and ultimately engine fires. Oil burning extends into the exhaust system and also damages catalytic converters leading to failure of those components and even fires. I understand Volvo issued Tech Journals to dealerships but, to date, this information has not been published to the consumer that we may be made hole. This is a major design flaw that creates an expensive and extremely dangerous situation affecting numerous engine parts subject to high levels of heat during engine operation. Any of these parts are susceptible to spontaneously combusting during operation and without warning. It is an extremely dangerous situation. However, I see no evidence of a recall on my vehicle.

NHTSA complaint #11713040 — an unverified report by a vehicle owner.

POWER TRAIN

On September 30, 2025, a 2016 Volvo XC90 T6 experienced sudden engine failure while driving westbound on I-75 (Alligator Alley) at highway speed. The vehicle abruptly went into reduced power mode (“turtle mode”) without warning. This forced the driver to stop on the roadside, creating a serious safety hazard in fast-moving traffic. Component/system that failed: Engine / Power Train. An independent repair facility performed diagnostics on October 6, 2025, including a compression test. Results confirmed that one cylinder had lost compression due to a failed cylinder head. The mechanic attributed this to excessive oil consumption from defective piston rings, a condition documented in Volvo technical bulletins. Inspection: The vehicle was inspected by an independent service center. Photos and test results are available for inspection upon request. The manufacturer was contacted and denied assistance, citing mileage, despite known oil consumption defects in this engine family. Safety risk: The sudden loss of power at highway speed put the driver and other motorists at risk of collision. With no advance warning, the driver was left stranded on a dangerous stretch of interstate. Reproduction: The failure has been confirmed through diagnostic testing and inspection by the independent service center. Manufacturer/police/insurance inspection: The manufacturer has been notified, but no inspection by Volvo has occurred to date. No police or insurance inspection was performed. Warning messages or lamps: Prior to the breakdown, no warning lamps or messages indicated impending failure. The first and only symptom was the sudden loss of power on the highway. Incident cause assessment: Based on mechanic’s findings, the underlying cause is piston ring/oil consumption defect leading to cylinder head failure. This defect is widely reported in Volvo vehicles with this engine and represents a safety-related condition.

NHTSA complaint #11694587 — an unverified report by a vehicle owner.

ENGINE

On September 30, 2025, a 2016 Volvo XC90 T6 experienced sudden engine failure while driving westbound on I-75 (Alligator Alley) at highway speed. The vehicle abruptly went into reduced power mode (“turtle mode”) without warning. This forced the driver to stop on the roadside, creating a serious safety hazard in fast-moving traffic. Component/system that failed: Engine / Power Train. An independent repair facility performed diagnostics on October 6, 2025, including a compression test. Results confirmed that one cylinder had lost compression due to a failed cylinder head. The mechanic attributed this to excessive oil consumption from defective piston rings, a condition documented in Volvo technical bulletins. Inspection: The vehicle was inspected by an independent service center. Photos and test results are available for inspection upon request. The manufacturer was contacted and denied assistance, citing mileage, despite known oil consumption defects in this engine family. Safety risk: The sudden loss of power at highway speed put the driver and other motorists at risk of collision. With no advance warning, the driver was left stranded on a dangerous stretch of interstate. Reproduction: The failure has been confirmed through diagnostic testing and inspection by the independent service center. Manufacturer/police/insurance inspection: The manufacturer has been notified, but no inspection by Volvo has occurred to date. No police or insurance inspection was performed. Warning messages or lamps: Prior to the breakdown, no warning lamps or messages indicated impending failure. The first and only symptom was the sudden loss of power on the highway. Incident cause assessment: Based on mechanic’s findings, the underlying cause is piston ring/oil consumption defect leading to cylinder head failure. This defect is widely reported in Volvo vehicles with this engine and represents a safety-related condition.

NHTSA complaint #11694587 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

On September 30, 2025, a 2016 Volvo XC90 T6 experienced sudden engine failure while driving westbound on I-75 (Alligator Alley) at highway speed. The vehicle abruptly went into reduced power mode (“turtle mode”) without warning. This forced the driver to stop on the roadside, creating a serious safety hazard in fast-moving traffic. Component/system that failed: Engine / Power Train. An independent repair facility performed diagnostics on October 6, 2025, including a compression test. Results confirmed that one cylinder had lost compression due to a failed cylinder head. The mechanic attributed this to excessive oil consumption from defective piston rings, a condition documented in Volvo technical bulletins. Inspection: The vehicle was inspected by an independent service center. Photos and test results are available for inspection upon request. The manufacturer was contacted and denied assistance, citing mileage, despite known oil consumption defects in this engine family. Safety risk: The sudden loss of power at highway speed put the driver and other motorists at risk of collision. With no advance warning, the driver was left stranded on a dangerous stretch of interstate. Reproduction: The failure has been confirmed through diagnostic testing and inspection by the independent service center. Manufacturer/police/insurance inspection: The manufacturer has been notified, but no inspection by Volvo has occurred to date. No police or insurance inspection was performed. Warning messages or lamps: Prior to the breakdown, no warning lamps or messages indicated impending failure. The first and only symptom was the sudden loss of power on the highway. Incident cause assessment: Based on mechanic’s findings, the underlying cause is piston ring/oil consumption defect leading to cylinder head failure. This defect is widely reported in Volvo vehicles with this engine and represents a safety-related condition.

NHTSA complaint #11694587 — an unverified report by a vehicle owner.

POWER TRAIN

Known supercharger leak on 2016 Volvo XC90 at 60,000 miles. Numerous reports of the same failure. Dealer and Volvo declined goodwill repair. Potential safety/fire issue if oil leakage worsens

NHTSA complaint #11685940 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

The rear two car doors will not open. It started months ago with the left side and now is both doors. This is dangerous if anyone in the rear of the vehicle should need to exit in a timely manner. The dealership knows this is an issue, but says they are not obligated to fix it for free because there isn’t a recall yet.

NHTSA complaint #11684873 — an unverified report by a vehicle owner.

AIR BAGS

SRS warning light and was told that is is due to a faulty misassembled wiring in the seat harness. Possibility of the airbags not deploying correctly in case of a crash. The dealer has confirmed that it is the seat harness that needs to be replaced. Due to the Month/Year of the vehicle it does not fall under the original recall which was only for vehicles that were manufactured between Jan/May 2015.

NHTSA complaint #11683113 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

SRS warning light and was told that is is due to a faulty misassembled wiring in the seat harness. Possibility of the airbags not deploying correctly in case of a crash. The dealer has confirmed that it is the seat harness that needs to be replaced. Due to the Month/Year of the vehicle it does not fall under the original recall which was only for vehicles that were manufactured between Jan/May 2015.

NHTSA complaint #11683113 — an unverified report by a vehicle owner.

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

Backup camera not activating when in reverse sporadically. My recorded video of this happening: [XXX] Issue has been brought to the Volvo dealership service department. Remedy from the Volvo service has been to update software but it has not corrected the issue. Multiple of owners have encountered the same issue which is widely documented online. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11682539 — an unverified report by a vehicle owner.