One problem related to engine head gasket failure has been reported for the 2004 Volvo XC90. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Volvo XC90 based on all problems reported for the 2004 XC90.
Early catastrophic engine failure. We bought this car new in 2004. Last year, at approx 35,000 miles, we had to replace the head gasket ($5000). Today I was told by our Volvo service center that the engine was blown and we needed a new one. ($12,500) this car has always been gently driven, has extremely low mileage yet has demonstrated that it's engine is a lemon.