2020 Volvo XC90 Engine Problems

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.

The vehicle shudders randomly when taking off from a stopped position around 18mph. The vehicle shudders randomly when slowing down to make a right turn. The vehicle shudders when driving at higher speeds. It's not a violent shudder, but those riding in the vehicle feel it as well. The safety concern is two fold in that there is a fear of losing control at an inopportune time. Secondly, the constant shuddering over time is going to result in damaging other part of the vehicle, particularly the engine, that will present a safety hazard while driving. The vehicle was purchased used(certified). The dealer replaced collapsed engine mounts on left and right side and considered it resolved. Forman at dealer stated it is common with XC90's to have engine shudder as if this should be accepted. Because the engine shudder is happening at higher speeds now, we're going to return to dealer, but I do not expect a solution. I've seen others report similar issues with shuddering on Volvo forums and I haven't seen 1 solution that worked. This is a problem in a lot of XC90's. The attached documents also contain some attempted fixes to correct a drifting issue.

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.