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Volvo XC90 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Volvo XC90 car and truck
repair procedures including Volvo engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Volvo XC90 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Volvo XC90 AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Volvo XC90 cars and light trucks from 1990+
Import Compressor Service -> Zexel Compressor -> Clutch Air Gap, Adjust
Vehicle: 2004 Volvo XC90 2.9 L6 GAS
- Inspect clearance around entire clutch disc using a feeler gauge.
- Disc pulley clearance should ...
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BRAKE SERVICE PROCEDURES FOR Volvo XC90 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Volvo XC90 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Component Service -> Assemble -> Cleaning & Inspection -> Disassemble -> Master Cylinder Overhaul
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
Master Cylinder Overhaul
Disassemble
- Remove reservoir from master cylinder.
- Drain fluid from reservoir, then remove seals.
- Remove circlip and withdraw pistons and return spring.
Cleaning & Inspection
- Polish inner surface of the master cylinder with a honing tool (cylinder grinding tool).
- Clean all pistons components and cylinder with methylated spirits.
- Blow compressed air into the equalizer and overflow holes.
- Inspect master cylinder bore for scoring, ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Volvo XC90 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Volvo XC90 cars and light trucks sold in the U.S. for 1980+.
Volvo -> Fuel Filter Scheduled Maintenance -> 2005-06 S80 & XC90 -> Normal Service -> Severe Service
Vehicle: 2005 Volvo XC90 V8 4.4 V8 GAS
Normal Service
Replace at 120,...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Volvo XC90 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Volvo XC90 cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Left Side -> Rear -> Right Side
Vehicle: 2010 Volvo XC90 V8 4.4 V8 GAS
Left Side
- Raise and support vehicle on lift.
- On models with AWD, remove drain plug and drain transmission fluid.
- On all models, remove front wheel lug nuts.
- Remove bolt for wheel hub driveshaft.
- Counterhold using a suitable tool in brake disc vents.
- Tap end of drive shaft approximately 20-25mm into wheel hub.
- Remove nut for ball joint and control arm. If ball joint pinion moves, counterhold end of lug using suitable tool.
- Disconnect ball joint pinion from control arm using suitable tool.
- Install cap nut using suitable tool on ball joint pinion.
- Tighten nut against control arm, the...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Volvo XC90 AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Volvo XC90 cars and light trucks sold in the U.S. from mid 1990's+.
Description
Vehicle: 2005 Volvo XC90 T6 2.9 L6 GAS
The TPMS (Tire Pressure Monitor System) has a CEM (Central Electronic Module), a remote RRX (Receiver Module), or a RKE (Remote keyless Entry), if keyless entry is installed. There are sensors mounted in the wheels and are activated when the vehicle exceeds 25 mph. The sensors transmit...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Volvo XC90 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Volvo XC90 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2008 Volvo XC90 V8 4.4 V8 GAS
- Disconnect both battery cables.
- Raise vehicle on suitable lift.
- Remove bolts securing suspension turrets.
- Remove bolts for upper engine mount on engine and remove upper cross stay mount.
- Open coolant reservoir cap.
- Remove bolts securing skid plate and lift forward to remove skid plate. There is a guide sleeve on upper mounting of skid plate. Skid plate must be lifted upward slightly in order to slide skid plate forward.
- Open drain plug on lower left bottom of radiator. Drain coolant in clean suitable container.
- Lower vehicle.
- Disconnect ECM connector.
- Remove air cleaner housing by disco...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Volvo XC90 AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Volvo XC90 cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
The cabin air filter should be replaced every 15,000 miles. The filter should be replaced more often if air flow is less than normal.
- Remove the sound proofing panel from under the passenger side of the instrument panel.
- Remove the cabin air filter cover retaining screws, then the cover, Fig. .
- Press down on the cabin air filte...
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MAINTENANCE LAMP RESET PROCEDURES FOR Volvo XC90 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Volvo XC90 cars and light trucks sold in the U.S. from 1990+.
Volvo -> Air Bag Warning Lamp ->
Vehicle: 2008 Volvo XC90 V8 4.4 V8 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Volvo XC90 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Volvo XC90 cars and light trucks from 1990+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2006 Volvo XC90 V8 4.4 V8 GAS
Lower
- Drain coolant into a suitable container.
- Reposition clamp at radiator and remove hose.
- Reposition clamp at coolant pipe and remove hose.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR Volvo XC90 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Volvo XC90 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2007 Volvo XC90 V8 Sport 4.4 V8 GAS
- Remove coolant reservoir mounting bolt and move reservoir aside.
- Remove upper engine torque rod and mounting bolts.
- Remove cover over tensioner and mounting bolts.
- Remove cover over idler pulley and mounting bolts.
- Remove cover over tensioner and mounting bolts.
- Disconnect engine ground cable from frame and move aside.
- Disconnect power steering pressure line from power steering pump and move aside. Be prepared to collect escaping fluids.
- Rotate auto-tensioner clockwise, using a suita...
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COMPONENT LOCATION DIAGRAMS FOR Volvo XC90 AUTOMOBILES
Component location diagrams for most Volvo XC90 cars and light trucks sold in the U.S. from 1990+.
 Door Components Diagram for 2008 Volvo XC90 3.2 3.2 L6 GASComponents on diagram: |
 Climate Control Components Diagram for 2006 Volvo XC90 V8 Ocean Race 4.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Volvo XC90 AUTOMOBILES
OEM drawn wiring diagrams for most Volvo XC90 cars and light trucks sold in the U.S.
 2006 Volvo XC90 V8 Ocean Race 4.4 V8 GAS Wiring DiagramComponents on diagram: |
 2005 Volvo XC90 2.5T 2.5 L5 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Volvo XC90 AUTOMOBILES
OEM TSB listings for most Volvo XC90 cars and light trucks sold in the U.S. from 1985+.
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Document: VVT SOLENOID, CLEANING - LACKS POWER, KNOCKING/RATTLING FROM ENGINE Vehicle: 2004 Volvo XC90 2.9 L6 GAS Symptoms: |
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Document: UPDATED PROCEDURE, PROPELLER SHAFT, REMOVAL/INSTALLATION Vehicle: 2008 Volvo XC90 3.2 Sport 3.2 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Volvo XC90 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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