I wanted to share an something I am currently experiencing to see if any has had similar experiences or if there is something else I should be doing to handle this situation.
2019 Volvo XC90 T6 Momentum
At 76,000 miles, I got a check engine light with code P0420. I took it to the dealership for diagnosis, knowing it was a catalytic converter inefficency code and should be covered under the emissions warranty to replace the catalytic converter. When I brought it in, I mentioned that I could hear what sounded like an exhaust leak from the exhaust manifold. On my previous volvo, I had few exhaust bolts back out and recognized the sound but thought since they would be in there, doing the catalytic converters, the dealership could confirm the leak location so I could develop a plan. Big mistake. The dealership noted the existence of an exhaust leak and denied the warranty claim for the catalytic converter stating that they will not replace the catalytic converter until the leak was fixed to avoid any potential damage to a new catalytic converter. I asked where it was and all they said was manifold area but did not provide me more information. I argued that the exhaust is part of the emissions system and if it is not functioning properly, I can not be at fault since it is not a maintenance item. There were no additional codes or signs of the car running rich from the leak. After discussion, and attempting to open a case with volvo customer care (that was denied), I reluctantly agreed that I would fix the exhaust leak and return the car for the warranty work to be completed. They quoted $3500 to fix the leak and although its a big job, I decided to handle it myself. I asked the service advisor verbatim, if I fix the leak, the dealership will replace the catalytic converter. He said yes and noted it in the service record notes. Ended up taking 22 hours and extracting a broken exhaust stud that was the source of the leak. Resealed the supercharger among other maintenance items while the car was out of service for almost a month and half. I don’t have a whole lot of spare time on my hands with the family commitments. After the work was done and I confirmed the leak was resolved, I went into the dealership and scheduled the service. They were out 21 days for next available appointment so I took what I could. Fast forward, I dropped the car off this morning for the service. The P0420 code was still present. What I didn’t notice is that with all the driving my wife had done with the few weeks prior to me starting the work and the 3 weeks after the work was done, the car had ticked over 80,000 miles to 80,328. It didn’t even cross my mind that this would be a problem since the issue was diagnosed and noted. I even had to pay a diagnostic fee for the original investigation. The dealership is refusing to replace the catalytic converter due to the car being brought in beyond 80,000 miles. This stipulation was never communicated. It is documented as a failed component inside the warranty window and I held up my end of the requirements to get it covered. The dealership claimed their regional manager denied the claim and there is nothing I can do. I called customer care to set up a case. The first gentlemen I spoke to said there is nothing they can do and that the regional manager has the final say. I asked him to open a case and he refused and said I need to work with the dealership. I went back to the dealership and spoke with the service advisor and the service manager, both refused to do anything more and stated my only chance of getting the warranty covered was through customer care. I called again and this time insisted a case has taken out. I gave all the information and stated my case. I am now waiting on a resolution. The dealership still has the car and is performing recall work I was also scheduled for. The service advisor told me that if the case is successful and they are told to complete the work, they will order the parts and I can bring the car back in to get the warranty done at the next appointment (adding more miles?). He offered to clear the code free of charge and explained that it doesn’t mean there is actually anything wrong with the car or its performance (which I am well aware of what the code represents). My biggest issue is, even if I accept that its just a “trivial” code and to ignore the light, I can’t morally sell the car without having it fixed. I do not want a car to get passed on to someone with a known issue that Volvo offered to hide and hope the code doesn’t pop up again. This whole situation is frustrating and hindsight is always 20/20. I would have rented a car for my wife and kids or borrowed a car or something to keep miles off if I had any idea this would be an issue. Am I missing something here? This just really doesn’t feel right to me and if customer care doesn’t come through I went through all of this for nothing.
I appreciate any feedback or insight into the situation