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Front wiring harness water ingress failure

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26K views 193 replies 44 participants last post by  jim5667  
#1 ·
I see across a few different threads what could be a common technical fault so wanted to open a new thread for others to quickly find and report if able.

@GTN @DDuck @kriand @derezzed all have like me confirmed or think they have the same symptoms as I.

symptoms include:
Visible damage (caused by shorted and melted components) to the front grille
Parking sensor failures
Permanent driver assist warning on dash

This could lead to being hard locked out from the car and/or electrics failing.

The cause is water ingress and corrosion to the front wiring harness that drives all the sensors and aids packed into the front grille.
Image
 
#185 · (Edited)
My 3 is not part of the recall VIN list but is an early build. VIN decoder shows RIDGEVILLE plant. Driving in heavy rain tripped multiple failure sensors and put it into turtle mode for several days. Ironically the turtle mode cleared by the time it was towed in (~5 days after) but it appears I'm not alone not near the long end of the waits. Mine has been there just 3 weeks. My problem is since my car shouldn't have been affected by the recall failure, they have to go through some checks to investigate and I likely have no replacement part priority. Resets did not clear the issue. In fact the in-cabin reset with the down arrows didn't reset the car, it required disconnecting the battery and one fuse.
 
#186 ·
Finally an update. After over 6 months being in the shop it's finally been fixed. I asked Volvo Warrington how many man hours the fix took. The guy laughed and told me most of it could only be done by a set few technicians in the UK and they had over 96 man hours clocked to the repair. So circa 3 weeks of work. I am guessing the whole car has been re wired from the front. It does make me think those people who have them fixed due to water in a day or a few days might be getting a botched job. So almost 190 days without the car.

Going to pick it up in a few days. It better be perfect...
 
#190 ·
So. I have the car back. 6 months later. It's was basically rewired all the front sensor are and the loop round the car. So far so good. Actually forgot how well it drives. Made the XC90 I was in look and feel like a car from the dark ages.

One issue I have is the car has been offline in the app for weeks. Thought this would sort itself once I picked it up but it's still offline. Tried hard and soft reset, removed app but still nothing. I really don't want to take it back in for this.
 
#192 ·
So. I have the car back. 6 months later.
I just got ours back too and felt similarly. It's a wonderful car. First rate quality and first rate drive. Our wait was well short of 6 months and I can't imagine waiting that long. That seems beyond the threshold of reasonable. As awful as it was to lose the car while they investigated or rather waited a month to investigate my failure (wasn't a recall vehicle but did about the same thing) it was the delay that was the worst part. Hopefully this is the last BIG failure. I love the car otherwise but that's a big ownership obstacle. Curious what % of owners would have bought the car all over again and of course how many saw similar problems.
 
#191 ·
I hope that works itself out for you. Great that you’ve got your car back.

My car is going in for the wiring replacement on Monday. I was rescheduled from a few weeks ago because they didn’t have all the parts in but Volvo Leatherhead have been great organising everything, including courtesy car.
 
#194 ·
Thought I would report in. After the 6 months wait and fix, I have had the car back for 2 weeks. It's a different car. Not one issue. No warning lights, never fails to open and close on approach with phone. Strangely it's more efficient too. I don't forgive the mess it's caused me. Only wish it had been as good as it is now from day 1 ( or month 1)