One problem related to starter 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.
Starting in 2011 and 3 other occasions vehicle would not start. Starter motor would not turn and system appeared to be dead. Battery was tested to be in good condition. Prior to these events electrical system behaved erratically with radio switching on and off, door locks not operating from remote key fob and windshield wipers erratically turning on and off. Lights and systems seemingly behaving erratically. Airbag warning lights came on. On first occasion system was reset and mechanic changed the starter motor. In hindsight I don't believe it was bad or caused of the problem. On second and third occasions after towing and repeated start attempts the engine started. Note that when attempting starts nothing happened when the key was turned (engine starter would turn or engage. No clicking sound associated with bad battery), on fourth occasion in July 2012 Volvo reported that central electronic module was bad and multiple fault codes were present. When informed that this was a seemingly a common problem on 2004/5 Xc90 with this model due to leaking grommet they denied this and stated that this was not the case for this vehicle. Module was changed at cost of $1,280.