2021 Volvo S90 Problems: 8 Known Issues

On the 2020-2021 Volvo S90, volvo Car USA recalled 2020-2021 S90 plug-in hybrid sedans under NHTSA campaign 25V179000 (Volvo reference R10312). On the affected S90 Recharge, the high-voltage battery may short circuit internally within a battery module when the battery has been charged to full and the car is sitting parked. Because the fault develops on a fully charged, stationary vehicle, an S90 left plugged in overnight in a garage is exactly the scenario of concern. NHTSA lists 7,483 units affected across the entire campaign, which also covers several other Volvo plug-in hybrid models — that figure is campaign-wide and is not a count of S90s. Volvo instructed owners not to charge the vehicle at all until the repair has been performed.

On the 2017-2023 Volvo S90, the Sensus infotainment system in the S90 suffers from significant lag, screen freezes, and black screen episodes. Since the system controls climate, seat heating, navigation, and vehicle settings through the central touchscreen, a crash renders many vehicle functions inaccessible. The system runs on a Tegra K1 processor that struggles with the software load, especially when running multiple features simultaneously. Volvo has released numerous software updates, and the transition to Google-based Android Automotive OS in 2024 addressed the hardware limitations but introduced new software bugs.

On the 2021 Volvo S90, 2021 S90L sedans (with 2020-2021 XC60 and XC90) built with the Continental integrated brake system (IBS) had hydraulic units in which the rotor and shaft were not welded to specification. Under a hard braking maneuver the rotor and shaft can separate inside the unit; the driver then experiences a sudden reduction in brake assist (a hard, dead pedal needing much more force) together with loss of ABS and Electronic Stability Control. Volvo filed the recall in September 2021 (NHTSA 21V716000).

On the 2017-2021 Volvo S90, s90 and V90 owners across 2017-2021 report a recurring 'Parking brake service required' warning, sometimes with the electric parking brake refusing to release or apply. Volvo has issued multiple bulletins: TJ 34647 (2019, revised through 2024) directs a software upgrade for the message, and TJ 32525 (2023) covers fault-tracing. Forum diagnoses on the Volvo Owners Club and Swedespeed show the physical causes when software does not clear it: the driver-side EPB motor wiring rubs on the chassis and fractures internally, corrosion at the caliper motor connectors, or lost communication with the parking-brake module in the trunk. A wiring fault appears 'regularly' on SPA models per forum technicians.

On the 2017-2022 Volvo S90, the T6 twin-charged engine in the S90 has a coolant crossover pipe (also called the coolant bridge or manifold) that runs between the cylinder head and the turbocharger. This pipe develops leaks at the O-ring seals, causing coolant loss that can lead to overheating if not caught. The plastic components in the coolant routing deteriorate from heat cycling. The leak is often slow and can be mistaken for condensation. Volvo updated the pipe design in 2021 with improved materials. The issue also affects XC60 and XC90 T6 models.

On the 2017-2025 Volvo S90, the electric auxiliary coolant pump develops a leak or fails, affecting cabin heating performance and turbo/supercharger cooling on T6 models. The pump circulates coolant to the heater core and turbo when the engine is off or at idle.

On the 2017-2024 Volvo S90, the S90 equipped with rear air suspension (standard on Inscription and optional on other trims) experiences air spring leaks and compressor failure, typically after 50,000-70,000 miles. The rear air springs develop cracks in the rubber bladder, causing slow leaks that worsen in cold weather. The compressor then overworks to compensate, eventually burning out. The S90 uses the same Continental air suspension components as the XC90, which share this failure pattern. Some owners report repeated failure within 20,000 miles of repair if only one component is replaced.

On the 2017-2025 Volvo S90, the Pilot Assist semi-autonomous driving system and adaptive cruise control intermittently become unavailable, displaying error messages. Camera or radar sensor obstruction, calibration drift, or software bugs can trigger the issue. Heavy rain, snow, or direct sunlight may also cause temporary unavailability.