2004 Volvo XC90 Volvo XC90 2004

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2004 Volvo XC90 repairs by problem area

Engine (32%)

Transmission and Drivetrain (15%)

Brakes and Traction Control (6%)

Suspension and Steering (20%)

Electrical and Air Conditioning (18%)

Paint, Rust, Leaks, Rattles, and Trim (5%)

Other (4%)

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Chart based on 282 repairs.
See TSBs and recalls for the 2004 Volvo XC90.

2004 Volvo XC90 electrical repair cost distribution

$2500+ (2%)

$1000 - $2499 (22%)

$500 - $999 (16%)

$100 - $499 (27%)

< $100 (33%)

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Chart based on 49 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2004 Volvo XC90 4dr SUV

turbocharged 268hp 2.9L I6 4-speed shiftable automatic AWD

58484 mi

US $1997
Replaced security system siren module for an internal failure. 
118500 mi Changed right rear brake light 
63000 mi

US $2281
We lost power to the lights, dash, wipers, windows and directional signals unexpectedly. First a DIM was replaced and the problem re-surfaced within days. Back to the dealer for a CEM. It seems fine now. 
127000 mi

US $1400
CEM Failure due to water leak, 2 fuse relays 
67000 mi

US $750
The alternator went out in this car less than 24 hrs. after purchasing it used from the dealer. They paid for the part. Mechanic was surprised at how long it took to replace it. 
52000 mi

US $899
Radio failed, had to replace the main control module. Volvo declined any assistance. 
145400 mi

US $850
driver window and ext. mirror does not work 
143000 mi radio (AM/FM only) temporarily stopped working twice, operational at present.  
161000 mi Alarm siren has been out for a few months. Not replaced to date. Problem reported with radio has not reappeared. Original battery still in good conditions after 8 years (a few Low Battery warnings ignored since 2008). 
180000 mi

US $1300
Ventilation fan failed. Mechanic said the HVAC controller had failed, most likely from an overamped fan motor (known failure). Replaced fan motor and controller. 
199000 mi

US $130
Air bag light was on. I had unplugged connectors at front passenger seat and rear middle seat to clean the carpet. Dealer completed a reset. No more problems. 
60000 mi Moldy, rotten smell emanating from the air vents after car has been washed or it has rained. No leaks inside the car (i.e. no wet floor mats or interior panels). Smell goes away after 2-3 days with the a/c running continuously. 3rd trip and no repair 
61000 mi Mildew smell coming out of vents after rain or car wash. 3rd visit to dealership for same problem. Dealer could not replicate problem (smell). 
88000 mi

US $500
Dealer found a/c was leaking, gave us a quote of $600 to repair. 
55000 mi

US $32
Recharged the A/C 
57000 mi

US $386
Radio & Nav system cutting out - replaced faulty Infotainment Center Control Module (ICM). 

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2004 Volvo XC90 4dr SUV

turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD

64900 mi

US $35
low beam wire connector failure. Needs replacement 
220500 mi

US $700
Replaced compressor Power seat control button broke off 
139300 mi

US $165
Siren module malfunctioned due to leaking internal battery. Causing sunroof to be nonfunctional. 

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2004 Volvo XC90 4dr SUV

turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD

126480 mi

C $1800
Repeatedly found car with flat battery in the morning. First visit (1 day): battery replaced. A week later, symptoms repeated. 2nd visit (2 days): shop discovered faulty diode on alternator. Alternator replaced with new unit. 
105000 mi

US $100
Scanned the check engine code and replaced the brake light switch 
184000 mi

US $180
xenon light bulb burned out, pricey to replace. 
206000 mi Interior air Fan motor 
115300 mi

US $1556
Cruise control stopped working. Software needed to be updated. 
109000 mi

US $153
Battery required replacement. The battery was OEM and lasted 10 years, 109,000...time for a new one! 
178200 mi

US $160
Right side air conditioning not cooling. Left side ok. Added refrigerant, wanted to replace o rings for $500 but I opted not to. 
190000 mi

US $430
Replaced all 10 bulbs in sound system. eBay parts were1/10th of dealer cost@$10 v$100. Replaced all 10 bulbs in sound system. eBay parts were1/10th of dealer cost@$10 v$100. 
194900 mi Turn signal (right) flashed fast, intermittently or not at all. Undid 3 T20 torx screws under steering column, then 2 Phillips screws. Removed turn signal switch. Remove last Phillips and cleaned contacts with alcohol and qtips.Replace all 
199305 mi

US $474
HID left bulb out, replaced both sides, $350 HID headlight bulb burned out. Replaced the pair. Parts very expensive. 
68200 mi

$35
position light bulb broken 
72540 mi

$2000
horn was malfunctioning and had to be replaced. 
56000 mi

US $506
Air conditioning not blowing cool air when idle. 
70000 mi

US $220
Radio display did not display 
147700 mi

US $1400
Rear wiper motor serviced. 
112000 mi

US $2000
headlights not functional. Fuse replaced, fixing lights, but computer warning light still malfunctioning intermittently, irritating. 
82240 mi

C $550
Module for sunroof and alarm system 
83800 mi initial problem with alarm module was not completed properly 
85220 mi faulty alarm module 
113460 mi Reverse sensor replaced. There were intermittent problems (ie. warning light coming on that it wasn't working) with the sensor leading up to the accident. No warning light at the time of the accident. It didn't work at all after the accident. It was repaired as part of the insurance claim. 
79360 mi

C $1100
needed new key fob, hatch back release and windshield washer pump 
96100 mi

C $250
The 6-CD changer failed. Could not play or even eject disks. Dealership quoted $1100 to replace it. Bought used one for $250 including shipping and replaced it myself. Many people report faulty CD changer. 

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2004 Volvo XC90 4dr SUV

turbocharged 161hp 2.4L I5 Diesel 5-speed shiftable automatic AWD

85300 mi

£80
Fuel level sender failed 
94000 mi

£75
ICM failed - audio was dying randomly. Fixed ICM at specialist car audio repair shop by replacing power transistor and resoldering dried out joints 

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2004 Volvo XC90 4-door

turbocharged 4-cylinder automatic 2WD

162000 mi

US $2500
console lights went out. told it was console- replaced for $1400. lights still out then dimmer replaced for additional $900. I was very angry because I asked if elect module would turn lights back on. 
169000 mi

US $246
AC out; fan continued to blow after car was turned off. Dealer adds FREON. Next day fan continued to run after car is off result-dead battery. Recharge switch for fan would not accept dial down continued to blow. Heat turn on dial down off. 
176000 mi

US $1100
Fixed AC. 
200000 mi The SR airbag light came on after my last oil change. I am not going to do anything about it. Im sick of this light that appears to mean nothing but cost. 

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2004 Volvo XC90 Electrical Problems

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2004 Volvo XC90 problems occur, check out our car reliability stats.