VOLVO
XC90
BRAKES 13-58
DRIVE TRAIN 13-41
ENGINE REPAIR 13-7
FUEL SYSTEM 13-38
PRECAUTIONS 13-7
SPECIFICATION CHARTS 13-2
STEERING AND
SUSPENSION 13-46
A
Air Bag 13-46
Disarming 13-46
Precautions 13-46
Alternator 13-7
Removal & Installation 13-7
B
Brake Pads 13-59
Removal & Installation 13-59
C
Caliper 13-58
Removal & Installation 13-58
Camshaft and Valve Lifters 13-25
Removal & Installation 13-25
Coil Spring 13-50
Removal & Installation 13-50
CV-Joints 13-46
Overhaul 13-46
Cylinder Head 13-14
Removal & Installation 13-14
D
Driveshaft 13-45
Removal & Installation 13-45
E
Engine Assembly 13-8
Removal & Installation 13-8
Exhaust Manifold 13-24
Removal & Installation 13-24
Final Drive 13-43
Removal & Installation 13-43
Front Crankshaft Seal 13-24
Removal & Installation 13-24
Fuel Filter 13-38
Removal & Installation 13-38
Fuel Injector 13-40
Removal & Installation 13-40
Fuel Pump 13-39
Removal & Installation 13-39
Fuel System Pressure 13-38
Relieving 13-38
Fuel System Service
Precautions.... ...13-38
H
Halfshaft 13-44
Removal & Installation 13-44
Heater Core 13-13
Removal & Installation 13-13
I
Ignition Timing 13-8
Adjustment 13-8
Intake Manifold 13-22
Removal & Installation 13-22
L
Lower Ball Joint 13-52
Removal & Installation 13-52
Lower Control Arm 13-55
Control Arm Bushing
Replacement 13-56
Removal & Installation 13-55
0
Oil Pan 13-34
Removal & Installation 13-34
Oil Pump 13-36
Removal & Installation 13-36
P
Piston and Ring 13-37
Positioning... ...13-37
R
Rack and Pinion Steering Gear.... 13-46
Removal & Installation 13-46
Rear Main Seal 13-37
Removal & Installation 13-37
S
Shock Absorber 13-48
Removal & Installation 13-48
Starter Motor 13-30
Removal & Installation 13-30
Strut 13-47
Removal & Installation 13-47
T
Timing Belt, Front Cover
and Seal 13-31
Removal & Installation 13-31
Transaxle Assembly 13-41
Removal & Installation 13-41
Turbocharger 13-20
Removal & Installation 13-20
V
Valve Adjustment... ...13-25
W
Water Pump 13-13
Removal & Installation 13-13
Wheel Bearing 13-56
Adjustment 13-56
Removal & Installation 13-56
13-2 VOLVO
XC90
SPECIFICATION CHARTS
ENGINE AND VE
Engine |
Code©
B5452T2
B6294T
Liters (cc)
2.4 (2435)
2.9 (2922)
Cu. In.
151
178
Cyl.
5
6
Fuel Sy|
MFI I
EFI ||
HICLE IDENTIFICATION
Model Year
>. Engine
DOHC
DOHC
Eng. Mfg.
Volvo
Volvo
Code
3
4
Year
2003
2004
MFI: Multi-port Fuel Injection
DOHC: Double Overhead Camshafts
GENERAL ENGINE SPECIFICATIONS
Engine Fuel Net Net Bore x Com- Oil
Displacement Engine System (Horsepower Torque @ rpm Stroke pression Pressure
Year Model Liters (cc) ID/VIN Type @ rpm (ft. Ibs.) (in.) Ratio @ rpm
2003
2004
XC90
XC90
2.4 (2435)
2.9(2922)
2.4 (2435)
2.9(2922)
B5254T2
B6294T
B5254T2
B6294T
MFI
EFI
MFI
EFI
j|208@5700
f 268@5200
J208@5700
j|268@5200
208@1500
280@i800
208@1500
280@1800
3.27x3.54
3.27 x 3.54
3.27x3.54
3.27x3.54
8.5:1
10.0:1
8.5:1
10.0:1
43@2000
NA
43@2000
NA
MFI: Multi-port Fuel Injection
ENGINE TUNE-UP SPECIFICATIONS
Valve
Engine Sparkplug Fuel Idle Clearance
Displacement Engine Gap Ignition Pump Speed (in.)
Year Liters (cc) IDA/IN (in|) Timing (psi) RPM In. Ex.
2003
2004
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T2
B6294T
B5254T2
B6294T
o.ofo
N|
o.olo
N!
10B
NA
10B
NA
51 ©
NA
51 ©
NA
850
650
850
650
HYD
HYD
HYD
HYD
HYD
HYD
HYD
HYD
NA: Not available
NOTE The Vehicle Emission Control Information label often reflects
if they differ from those in this chart.
B: Before top dead center
HYD: Hydraulic
©At idle
Deification changes made during production. The label figures must be used
VOLVO
XC90 13-3
CAPACITIES
Year Model
2003
2004
XC90
XC90
Engine
Engine Oil with Transfer
Displacement Engine Filter Transmission Case
Liters (cc) ID/VIN (qts.) (pts.) (pts.)
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T2
B6294T
B5254T2
B6294T
5.8
7.6
5.8
7.6
15.0
NA
15.0
NA
©
©
©
©
Drive
Axle
Front Rear
(pts.) (pts.)
—
—
—
—
NA
NA
NA
NA
Fuel Cooling
Tank System
(gal.) (qts.)
19.0
19.0
19.0
19.0
NA
NA
NA
NA
NA: Not available
NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained.
© Included in transmission amount
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS
All measurements are given in inches.
Engine
Displacement Engine
Year Liters (cc) ID/VIN
2003
2004
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T2
B6294T
B5254T2
B6294T
Crankshaft Connecting Rod
Main Brg. Main Brg. Oil Shaft Thrust Journal Oil Side
Journal Dia. Clearance End-play on No. Diameter Clearance Clearance
2.5584-
2.5592
2.5584-
2.5592
2.5584-
2.5592
2.5584-
2.5592
0.0007-
0.0017
0.0007-
0.0017
0.0007-
0.0017
0.0007-
0.0017
0.003-
0.007
0.003-
0.007
0.003-
0.007
0.003-
0.007
5
5
5
5
1.9679-
1.9685
1.9679-
1 .9685
1 .9679-
1 .9685
1.9679-
1 .9685
NA
NA
NA
NA
0.006-
0.018
0.006-
0.018
0.006-
0.018
0.006-
0.018
NA: Not available
VALVE SPECIFICATIONS
Spring Spring
Engine Seat Face Test Installed
Displacement Engine Angle Angle Pressure Height
Year Liters (cc) IDA/IN (deg.) (deg.) (Ibs. @ in.) (in.)
2003
2004
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T2
B6294T
B5254T2
B6294T
45
45
45
45
44.5
44.5
44.5
44.5
NA
NA
NA
NA
NA
NA
NA
NA
Stem-to-Guide Stem
Clearance Diameter
(«n.) (in.)
Intake Exhaust Intake Exhaust
0.0012-
0.0024
0.0012-
0.0024
0.0012-
0.0024
0.0012-
0.0024
0.0015-
0.0028
0.0015-
0.0028
0.0015-
0.0028
0.0015-
0.0028
0.2738-
0.2750
0.2738-
0.2750
0.2738-
0.2750
0.2738-
0.2750
0.2734-
0.2746
0.2734-
0.2746
0.2734-
0.2746
0.2734-
0.2746
NA: Not available
13-4
VOLVO
XC90
PISTON AND Rlf G SPECIFICATIONS
All measurements are given in inches.
Engine
Displacement Engine Piston
Year Liters (cc) IDA/IN Clearance
2003
2004
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T/2
B6249T
B5254T/2
662491
0.0004-
0.0012
0.0004-
0.0012
0.0004-
0.0012
0.0004-
0.0012
Ring Gap Ring Side Clearance
Top I Bottom Oil Top Bottom Oil
Compl Comp. Control Comp. Comp. Control
0.047
0.047
0.047
0.047
0.069
0.069
0.069
0.069
0.118
0.118
0.118
0.118
0.0020-
0.0033
0.0020-
0.0033
0.0020-
0.0033
0.0020-
0.0033
0.0011-
0.0026
0.0011-
0.0026
0.0011-
0.0026
0.0011-
0.0026
0.0008-
0.0022
0.0008-
0.0022
0.0008-
0.0022
0.0008-
0.0022
TORQUE SPE(
All readings
:IFICATIONS
in ft. Ibs.
- -
Engine Cylinder Main Rod Crankshaft
Displacement Engine Head Bearing Bearing Damper Driveplate
Year Liters (cc) IDA/IN Bolts Bolts B| Its Bolts Bolts
2003
2004
2.4 (2435)
2.9 (2922)
2.4 (2435)
2.9 (2922)
B5254T/2
B6249T
B5254T/2
B6249T
©
©
©
©
®
©
©
©
1
1
p)
E '"
133
219
133
219
®
®
®
®
Manifold
Intake Exhaust
15
15
15
15
18
18
18
18
Spark
Plugs Wheels
20
22
20
22
102
102
102
102
©Stepl: 14ft. Ibs.
Step 2: 43 ft. Ibs.
Step 3: Plus 130 degrees
©Tighten cylinder block, intermediate section, in stages:
Step 1: M10 bolts: 15ft. Ibs. (20mm)
Step 2: M10 bolts: 33 ft. Ibs. (45mm)
Step 3: M8 bolts: 18 ft. Ibs. (25mm)
Step 4: M7 bolts: 13 ft. Ibs. (17mm)
Step 5: M10 bolts: Plus 90 degrees
@ Connecting rod with treated toothed surface between the connecting rod and cap, screw
withfphoulder:
Stetfl: 14ft. Ibs.
Stett 2: plus 90 degrees
Conr|ecting rod with fracture surface between the connecting rod and cap, fully threaded
screi)
SteJ>1: 22ft. Ibs.
Stei 2: Plus 90 degrees
©Ste|l: 33 ft. Ibs.
Sten 2: Plus 65 degrees
© 15 ffl Ibs., plus 90 degrees
VOLVO
XC90 13-5
WHEEL ALIGNMENT
Caster Camber
Year
2003
2004
Model
XC90
XC90
F
R
F
R
Range
(+/-Deg.)
1.00
—
1.00
—
Preferred
Setting
(Deg.)
+5.70
—
+5.70
—
Range
(+/-Deg.)
0.90
1.00
0.90
1.00
Preferred
Setting
(Deg.)
-0.33
-0.04
-0.33
-0.04
Toe-in
(in.)
-0.20+/-0.10
0.30+/-0.20
-0.20+/-0.10
0.30+/-0.20
Kingpin
Inclination
(Deg.)
—
—
—
—
TIRE, WHEEL AND BALL JOINT SPECIFICATIONS
Year Model
2003
2004
XC90
XC90
OEM Tires Tire Pressures (psi)
Standard Optional Front Rear
P225/70R16
P235/65R17
P235/65R17
none
®
©
©
©
Wheel Ball Joint
Size Inspection
7-JJ
7-JJ
NA
NA
OEM: Original Equipment Manufacturer
PSI: Pounds Per Square Inch
NA: Not available
© See placard on vehicle
BRAKE SPECIFICATIONS
All measurements in inches unless noted
Front Brake Disc Rear Brake Disc Bracket Mounting
Original Minimum Maximum Original Minimum Maximum Thickness Bolts Bolts
Year Model Thickness Thickness Runout Thickness Thickness Runout Front Rear (ft. Ibs.) (ft. Ibs.)
Minimum
Lining
Thickness
Brake Caliper
2003
2004
XC90
XC90
NA
NA
0.984
0.984
0.002
0.002
NA
NA
0.669
0.669
0.002
0.002
0.12
0.12
0.12
0.12
©
©
20
20
NA: Not available
© Caliper holder mounting bolt: 26 ft. Ibs. plus 60 degrees
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Description
The 2006 Volvo XC90 Service & Repair Manual is a valuable resource for both professional mechanics and DIY enthusiasts. It provides comprehensive guidance for repairing and maintaining the 2006 Volvo XC90 model.
Key features of the manual include:
- Step-by-step instructions for various repairs and maintenance procedures.
- Comprehensive coverage of engine repairs, electrical systems, and more.
- Detailed diagrams to visualize different components and systems of the vehicle.
- Troubleshooting guides to identify and resolve problems.
- Regular updates to ensure access to the latest information and instructions.
Models covered by the manual:
- 2006 Volvo XC90 Base Model
- 2006 Volvo XC90 2.5T
- 2006 Volvo XC90 T6
Whether you have the base model, 2.5T, or T6, the 2006 Volvo XC90 Service & Repair Manual provides the necessary information to confidently tackle any maintenance or repair task for your vehicle.
