Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Volvo XC90 owners, lightly cleaned up (personal details are redacted by NHTSA).
While driving on the highway "SRS urgent" text came on, also hear clicking sounds under dash on driver side, then dashboard indicator lights completely disappear (speed, fuel, temperature, etc) . Extremely hot under driver side dash. Fortunately, still able to steer and brake. This has happened twice now. Mechanic believes most likely CEM failure or DIM failure. My vehicle also has a wet A-pillar fabric (Volvo forums indicate possible cause of failure). I removed drivers A-pillar and found a clogged drain tube from the sunroof. However, did not notice any obvious signs of water inside the vehicle, though it hasnt rained for over a month when this happened.
Unsure of what the issue is with the vehicle but smells like gas in my garage and I found a recall I was never notified about I moved from Washington to Las Vegas and never received any info regarding the fuel pump recall as well as a noise that's been going on for a year now when I drive at 60 miles an hour I've had it looked at and no one seems to know what that issue is
My 2004 Volvo XC90 with a 2.5t engine, 7 pass, intermittently and inadvertently stalls while driving it. It is scary because all electrical goes off, instrument panel, radio, lights, etc, several warning messages appears, such ABS, air bags failure, brake failure, engine failure, etc. It won't respond to acceleration and brakes are very hard to push, the engine does not stop. I have to stop, turn it off, wait few minutes, then start it, everything comes to normal again but with the check engine and the air bags message, then after some minutes of driving the same stalling and electrical issues happen again. This is serious because you are on freeway and you loose brakes and engine control, no information in instrument panel, etc. …
Car lost all power and message window read "reduced engine performance". We were traveling in the left lane and had to coast through traffic to the shoulder. There was absolutely no throttle response, so we shut the car off. Upon restarting it, the message disappeared and we were able to continue our trip. It happened again, and we reset it once again. We stopped at the first Volvo repair facility we found and had them scan all the computers using the Volvo diagnostic equipment. The code they retrieved was ECM-981a. They cleared our computer using the Volvo computer, but the problem returned on our return home. We were barely able to get out of the way of a semi barreling upon us! The problem still persists, and I finally went to my computer to find some information on my own. Apparently, this is not so uncommon a problem with these cars. …
Exiting driveway in reverse, upon switching to drive the dashboard lights started flickering and a jerk was felt in the transmission. Soon the dashboard gauges and the indicators went dead. Several error messages quickly "scrolled" (brake failure, airbag failure, ABS failure, engine failure) then the check engine light came on and remained on. No power to dashboard controls (gauges dead, no lights/turn signals, no radio). Front windows work, but not rear. Vehicle drives as if in low gear. Unsafe to drive so had towed to dealer. They are running diagnostics so tbd on specific issue and cost to repair. Concerned as no recall and situation is so dangerous (what if I'd been on freeway!) Volvo should recall all the 2004 XC90 as others report same defect
I have a Volvo XC90 2004. I was driving and suddenly I heard a noise under the car. I stop the car and call my road service provider to send me a tow truck. We took the car to the auto center to have it inspected, they call me to give me bad news they said it was the transmission shaft, something coming out apart and that will be expensive to fix and that I needed to take it to Volvo dealer to get it fix . I was in shock. I didn't expected this so soon my Volvo car it has 87,000 miles and I feel this is a manufacturer malfunction problem . This should be a recall, its too soon to give me this headache please investigate this matter soon to help others I will really appreciated if I have a answer soon.
Tl-contact owns a 2004 Volvo XC90 ---- contact called Volvo dealer in white plains ny... Contact stated airbag light came on while driving and was on for a month.... Vehicle stalled going 50mph ... Power steering went out on main highway vehicle lost power and shut off.... Vehicle restarts and then shuts off again after going a couple miles...spoke with mechanic at dealership who stated that airbags are recalled....mechanic by the name of anthony.... Told contact that airbag light being on was not a big deal....that airbag was faulty so it would not deploy in accident........ 0 recalls associated with this VIN.. Cb
When traveling at high rates of speed (on the highway) the car completely shuts off. The dashboard and all electrical shuts off, the hazards do not seem to work or the turn indicators, ABS does not work so it is a very slow heavy stop. This happened to me in this car one other time in 2010, and there was an immediate computer module upgrade issued.
Tl* the contact owns a 2004 Volvo XC90. While driving 65 MPH, the engine rpms decreased as if the brake pedal were depressed. The vehicle was not taken to a dealer or repaired and the failure recurred. The manufacturer was not notified of the failure. The VIN was not provided. The failure mileage was 135,000....updated 01/27/16
Tl* the contact owns a 2004 Volvo XC90. While driving 40 MPH, the vehicle stalled without warning. The vehicle was taken to an independent mechanic. The technician was unable to diagnose a failure. The manufacturer was not made aware of the failure. The failure mileage was 122,000.
Engine complaints in other XC90 years
Frequently asked questions
How common are engine problems on the 2004 Volvo XC90?
NHTSA has 52 complaints about the engine & cooling of the 2004 Volvo XC90, 11% of the model year's 462 complaints. The component named most often is engine (6 mentions).
Is there a recall for 2004 Volvo XC90 engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Volvo XC90, though it has 6 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Volvo XC90 engine problems start?
Half of the complaints with a recorded mileage happened before about 91,000 miles, and 4% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.