EPA # 3

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)

2.5 Liters, 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

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4.5	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

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5. 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.

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