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Volvo Cars of North America Emission Defect Information Report

EDIR No. 09006D01A
September 23, 2009 1. Manufacturer's Corporate Name: Volvo Cars of North America, LLC
2. Component Description Component Name: Fuel Pump Unit Description of Component: The fuel pump unit delivers fuel from the gas tank to the fuel rail.
3. Failure Description In hot climate conditions, over an extended period of time, the fuel pump mounting flange may develop stress crazing due to temperature cycling. The most common symptom is fuel smell. Rarely, this condition may be experienced as longer cranking time at vehicle start,

4. Affected Vehicles by Test Group

4.1 Test Group:

Model Year: Models Involved: Engine Description:

Sales Area:

4.2 Test Group:

Model Year: Models Involved: Engine Description:

Sales Area:

4.3 Test Group:

Model Year: Models Involved: Engine Description:

Sales Area:

4.4 Test Group:

Model Year: Models Involved: Engine Description:

Sales Area: 4VVXX2.52U2T 2004 S60, V70, XC70, S80, XC90, S40 T5 B5254T2 (59, 68) -2.5 Liters, 5 Cylinders, OHV, SOHC, CVVT, 20-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S), HA/FS, Charge Air Cooler, Three-Way Catalytic Converter (TWC) 50 States

4VVXV2.52L1T 2004 S60, 560R, V70, V7OR, C70 Coupe, C70 CAB 85254T3 (52), B5234T3 (53), B5234T9 (62), B5244T7 (63) 2.5Liters, 5 Cylinders, OW, SOHC, CVVT, 20-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S), HA/FS, Charge Air Cooler, Three-Way Catalytic Converter (TWC) 50 States

4VVXV2.92U1T 2004 S80 B6294T (91) 2.9 Liters, 6 Cylinders, OHV, DOHC, CWT, 24-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S), HA/FS, Charge Air Cooler, Three Way Catalytic Converter (TWO) 50 States

4VVXT2.92U1T 2004 XC90 AWD B62941(91) – 2.9 Liters, 6 Cylinders, OHV, DOHC, CVVT, 24-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S) , HA/FS, Charge Air Cooler, 2x CCC, lx UFC 50 States

1 of 3 Volvo Cars of North America, LLC EDIR No. 09006001A 2009-09-234.5 Test Group: 4VVXV2 92U1N Model Year: 2004 Models Involved: S80 Engine Description: E36294S2 (92) - 2.9 Liters, 6 Cylinders, OHV, DOHC, CWT, 24-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S) , Dual HA/FS, Charge Air Cooler, 2x Manifold-Close-Coupled Catalysts,lx UFC Sales Area: 50 States

4.6 Test Group: 5VVXX02 5U2T

Model Year: 2005 Models Involved: , S60, V70, XC70, XC90, S80 Engine Description: B5254T2 (59, 68) - 2 5 Liters, 5 Cylinders, OHV, SOHO, CVVT, 20-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI). Heated Oxygen Sensors (H025), HA/FS, Charge 'Air Cooler, UFC Sales Area: 50 States

4.7 Test Group: 5VVXV02 5L2T

Model Year: 2005 Models Involved: S6OR, V7OR, S60, V70 Engine Description: B5254T3 (52), B5254T5 (54) - 2 5 Liters, 5 Cylinders, OHV SOHC, CVVT, 20-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S), HA/FS, Charge Air Cooler, UFC Sales Area: 50 States

4.8 Test Group: 5VVXT02.9U1T

Model Year: 2005 Models Involved: XC90 T6 AWD Engine Description: B6294T (91) – 2.9 Liters, 6 Cylinders, OHV, DOHC, CVVT, 24-valve turbocharged engine with OBDII, Bosch ME7 Engine Management, Sequential Fuel Injection (SFI), Heated Oxygen Sensors (HO2S) , HA/FS, Charge Air Cooler, Three Way Catalytic Converter (TWC) Sales Area: 50 States

2 of 3 Volvo Cars of North America, LLC - EDIR No. 09006D01A 2009-09-235. Affected Vehicle Population

5.1 Sales volumes are from Volvo's warranty records. Estimated affected vehicle populations are based upon screening of model year 2004 fuel pumps. There was a fuel pump production change part-way through model year 2005. Therefore, for model year 2005, Estimated* Affected Vehicle populations may be lower than noted. Investigation is ongoing.
Currently Affected Vehicle Population by Test Group
Test Group
4VVXX2.5U2T 4VVXV2.52L1 T 4VVXV2.92U1T 4VVXT2.92U1T 4VVXV2.92U 1N 5VVXX02.5U2T 5VVXV02.5L2T 5VVXT02.9U 1T US Sales
89,933 10,366 4,006 25,988 6,829 73,627 3,165 9,294 Screened Claim % Est. Affected Vehicles
1.19 % 1,070 3.51 % 363 2.63 °/0 105 2.39 °A 621 1.55% 105 *0.39 `)/0 287 *0.98 31 *0.89 % 88
Total Affected Vehicles: 2,670

5.2 Assembly plants producing the potentially affected vehicles are:

Volvo Cars Torslanda Volvo Cars Europe Industry SE-405 31 Goteborg JU.F. Kennedylaan 25 Sweden B-9000 Ghent Belgium

6. Description of Failure Impact The most common symptom is fuel smell, which would customarily motivate the customer to seek immediate dealer contact and repair. Based upon analyzed claims, fixed-right-first-time performance has been 100 percent. The customer may also experience a longer cranking time at engine start. Warranty claim analysis and engineering judgment have lead to a determination that the failure mainly affects Volvo vehicles in hot states.

7. Available Emissions Data None.

8. Anticipated Manufacturer Follow-up Follow-up will be planned as a response to and according to timelines that will be established for NHTSA PE 09-039.

3 of 3 Volvo Cars of North America, LLC -EDIR No.09006D01A 2009-09-23