Finally, we look to have a solution to the mysterous cold air leak in the driver's side footwell of our 2005 XC90 V8. Turns out there were two issues contributing to the problem:

1) Warped CEM cover

2) Not all fasteners for CEM cover and adjoining electronics cover in place

The correction was replacing the CEM cover with a new, straight one and insuring ALL clips/fasteners were in place for the CEM cover as well as an adjoining cover.

For the other folks who emailed me reporting similar issues, this should help your dealer resolve the problem.

Thanks!

I am going to the dealer after tomorrow -printed out your initial and this posts...give it to them, see what happens.