| 1 | 0 | 3 | 4 | 3 | 4 |
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%)
Chart based on 282 repairs.
2004 Volvo XC90 engine repair cost distribution
$2500+ (3%)
$1000 - $2499 (20%)
$500 - $999 (24%)
$100 - $499 (28%)
< $100 (25%)
Chart based on 75 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2004 Volvo XC90
Engine not specified
| 51460 mi C $200 |
Broken motor mount. |
| 70000 mi £800 |
Car goes into protection mode for no reason |
| 85000 mi | Engine suddenly died while daughter was driving. She ended up in the oncoming lane. Lucky no one was in it at the time. Towed to the nearest Volvo dealer who could find nothing wrong with it (except $2500 list of unrelated repairs). Sold instead. New upper torque mount (broken). Sold instead of repairing. New coolant reservoir (leaking). Sold instead of repairing. New Air Hose (leaking). Fix ignition key (Key part wouldn't stay horizontal). Sold instead of repairing. |
| 95700 mi US $195 |
upper motor/torque mount replaced |
| 150000 mi | ACV cracked |
| 246000 mi US $300 |
Cracked top engine mount |
2004 Volvo XC90 4dr SUV
turbocharged 268hp 2.9L I6 4-speed shiftable automatic AWD
| 128000 mi US $640 |
Motor mounts and torque mount replaced |
| 141700 mi US $539 |
Two of six ignition coils failed. Replaced two ignition coils and six spark plugs at the same time. |
| 149500 mi US $640 |
Ignition lock cylinder failed. Car was towed to dealership and its ignition lock cylinder was replaced. $640 includes $91 towing charges. |
| 129000 mi US $2261 |
check engine light. Front and rear O2 sensors replaced. Right engine mount broken: replaced. |
| 136200 mi US $50 |
Engine mount |
| 137900 mi US $4300 |
oil on drive belt |
| 147300 mi US $435 |
Oil leak |
| 155000 mi US $400 |
Replaced radiator |
| 53985 mi US $2944 |
Replaced both Turbochargers |
| 65772 mi US $793 |
Replace Thermostat and temperature sensor housing. Replace engine torque mount Replaced engine torque mount. Check engine light eluminated: Replaced engine coolant temp sensor and thermostat. |
| 44866 mi A $119 |
Replaced oil cooler hoses due to hose fail and resulting water/coolant leakout. Replaced oil cooler hoses due to hose fail and resulting water/coolant leakout. |
| 58000 mi US $1 |
Motor mount was broken |
| 57000 mi | Seal on Fuel Tank was broken during wheel bearing repair in May/June 2008. Terribly strong smell of leaking fuel. Car not driveable. Dealer repaired under factory warranty w/o admitting fault. |
| 88000 mi US $500 |
Dealer found engine was leaking coolant, gave us a quote of $1500 to repair. |
| 145400 mi US $850 |
replace ignition coil and all spark plugs |
| 108000 mi US $1080 |
Replaced broken top engine mount ($85). |
| 180000 mi US $1300 |
Coolant is leaking. In searching for leaks, mechanic noted that a turbocompressor oil leak weakened two short cooling system hoses. Replaced those hoses. Tightens another cooling hose to stop leak. Leak slowed, not all the way gone yet |
| 183000 mi US $115 |
Coolant leak continues. Found leak at the upper radiator connection. Replaced upper hose. Still leaking under pressure, identified a likely crack at the radiator connection. Radiator needs to be replaced. Keeping pressure off to avoid leak |
| 192000 mi US $250 |
Water pump started to leak badly--radiator okay. Having the level sensor of the coolant was extremely valuable to manage the leak while traveling. Since it was almost time for a new timing belt, that was done too, minimizing the actual cost of the repair. |
| 198000 mi | Just a note that an oil leak getting worse, possibly at a turbo. |
| 199000 mi US $130 |
I have a leak of engine oil that has been getting worse. Got it looked at during diagnosis visit. Told the seal of the oil pan needs replacing. Expensive replacement! About $700. Lots of hours... Will wait a bit. |
| 201000 mi | Oil leak never fixed. |
| 197000 mi US $1200 |
Coolant leak traced to water pump. Oil leak. |
| 56420 mi C $2000 |
Oil leak, timing belt. |
2004 Volvo XC90 4dr SUV
turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD
| 155000 mi US $685 |
Replaced spark plugs and defective ignition coil. Also fuel filter |
| 95000 mi US $370 |
found slight oil leak from turbo. |
| 99000 mi | Fuel pump recall. Gas smell in car. Fuel pump had a leak. |
| 134000 mi US $1800 |
replace fuel pump, water pump and timing belt. |
| 105500 mi US $400 |
Radiator cracked. |
| 120000 mi US $600 |
Catalytic Converter was gone. Couldn't pass Calif emissions test. Indy Mech replaced with part from used XC. Cat's been gone for about 10 months now but I just had it fixed. no problems sensed but just couldn't pass emissions. |
| 66000 mi US $1500 |
O2 sensors and MAF sensor replaced |
| 182000 mi US $200 |
Replaced turbo. Replaced MAF. Replaced oxygen sensor |
| 103300 mi US $1100 |
Tune up and replaced cracking timing belt. Bearing behind timing belt, some rust. |
| 109500 mi US $659 |
Speed Sensor and Brkae sensor failed |
| 92000 mi US $1200 |
Reduced engine performance. Needed new electronic throttle module |
| 198700 mi US $120 |
motor mounts were replaced |
| 121000 mi US $300 |
Hangers on exhaust system broke, repaired with aftermarket hanger kit. Check engine light was due to bad gas cap replaced with original equipment also due for state inspection. |
2004 Volvo XC90 4dr SUV
turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD
| 202000 mi US $1100 |
Radiator leaking fluid. |
| 151000 mi US $2000 |
MAS computer chip AGAIN |
| 152300 mi US $600 |
yet ANOTHER computer chip went out and needed replacing |
| 119200 mi US $120 |
Light on for intake camshaft timing. Previously purchased timing belt per service manual replacement @ 120k. Replaced timing belt, no issues. Immediately after replacement noticed lifter noise, checked timing, still OK. Lifter noise. Noise got louder. Low oil pressure light came on. Failed connecting rod bearing. Engine oil was full. Cause still unknown. Regular dealer maintained vehicle with records new up to 105k. Work still in progress. |
| 120900 mi C $550 |
Engine not running smoothly, power loss. Sounded like not all cylinders firing. Shop found #3 cylinder ignition coil not working. Unit replaced. |
| 187000 mi | Replace worn engine mount |
| 210000 mi US $1370 |
Replace PCV / flame trap system And cracked boost hose. |
| 106000 mi US $80 |
The "short" and "long rails" that anchor & protect the fuel line and evaporative return that run from the fuel tank to the engine compartment beneath the cabin floor fell off the car and had to be replaced. Not accident/incident-related. |
| 40300 mi | Rubber engine mounts needed replaced |
| 72000 mi | Also new radiator. |
| 73000 mi | Replacement of a bad Turbo Control Valve. |
| 70000 mi US $25 |
Had code P0638 faulty throttle sensor come up. Code was reset and has not come back since. |
| 70500 mi US $300 |
Spark plug failure. Replaced all. |
| 100720 mi C $400 |
engine mount broken |
| 101880 mi C $1200 |
Replaced water pump and timing belts. |
| 102920 mi C $600 |
Due to blown gasket from overheating at the shop's fault, the engine was rebuilt at the shop's expense, except for parts costs of timing belt, water pump, spark plugs replaced with new items. |
| 148000 mi US $260 |
There was a trottle body code found. The car was running very rough the check engine light was on and the engine service required warning was on. The shop did an induction cleaning to see if it would help. Still running smooth so far. |
| 96100 mi C $260 |
Oxygen sensor failed. Dealership wanted to replace both which would have cost me $1200. I friend replaced only the faulty one: part + his labor = $260. Everything works fine since then. |
| 83700 mi C $45 |
rear exhaust bracket that holds muffler in place had rusted through and was causing a "rattle" i simply reinforced the bracket..it now seems to be working fine |
| 93000 mi C $500 |
regular maintenance term plus replace clasps for fuel line |
| 112000 mi US $2000 |
leak in exhaust system. No safety issue and would cost over $1K to replace. Only effect is slightly noisier exhaust system. |
| 128000 mi US $25 |
intermittent thick smoke from exhaust. Possibly coolant leaking into combustion chamber. |
| 132000 mi US $150 |
Oil pump system failure |
2004 Volvo XC90 4dr SUV
turbocharged 161hp 2.4L I5 Diesel 6-speed manual AWD
| 112000 mi £600 |
The car was misfiring, so they replaced some sensors and when we got the car back it was still misfiring, so we sent it back and they played with it a bit more and finally fixed the problem. We did not get a clear answer from them as to the problem, but the car is running well again. |
2004 Volvo XC90 4-door
turbocharged 6-cylinder automatic 2WD
| 53000 mi | Coolant tubing needed replacement. Small leak under pressure. |
2004 Volvo XC90 4-door
turbocharged 5-cylinder diesel automated manual AWD
| 74000 mi £430 |
Geartronic gearbox oil change and reprogrammed. |
| 92000 mi | Fuel pipe from fuel pump leaking |
2004 Volvo XC90 4-door
turbocharged 4-cylinder automatic 2WD
| 189700 mi | engine message "reduced engine performance". local auto part shop was unable to get a good reading on problem when plugging into their system. nothing done to date. |
| 192100 mi US $700 |
24May rearend, towbar re-welded; Car now drag & hik-up. Local shop paid 2 tuneup $520 still dragng;diagnostic $0,catlyt converter quote $1700, dealer diagnostic paid $121 quote $5000. Indep volvo Spec shake dust from filters quote $0 no code. |
| 201500 mi | I picked the car up, and drove 10 miles, and the skid cover came off. $129.00- I had it removed. |
| 209300 mi US $16 |
Car hesitating as if to hickup; the engine light's on; I experienced this before autozone recommended adding an additive to fuel which worked. Last year dealer suggested $2300 for tune up, and a local shop $5000 for the same problem. |
2004 Volvo XC90 4-door
5-cylinder automatic AWD
| 140000 mi US $2487 |
Replace Turbo Large Hoses. |
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See TrueDelta's information for all Volvo models.
