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Sounds like you need to remove the blower motor and see what's up. I've done this on our S80 which I believe uses the same HVAC system. Memory tells me I had to remove the glove box and, of course, the passenger's under-dash panel. On the S80 I had to start by removing the RH side piece of the center console, then the under-dash panel. Not sure if your XC90 will be like that. The motor is held in with about half a dozen torx screws - probably #25 torx. I recall one of those screws, on the forward side of the blower, being a little hard to access due to the slope of the passengers foot well. It's not an overly difficult job.
Oh, BTW, in my case the problem was that the blower squirrel cage was bound up with some sort of like terry cloth material that is apparently used as some sort of "gasket" up in the HVAC unit somewhere and had dropped down into the blower. I pulled out the remains and ever since then we get a certain amount of uncontrolled/uncommanded outside air making its way into the passenger's footwell area when traveling at highway speed. Kinda sucks in the winter.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (STILL not road worthy!)
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