2006 Volvo XC90 Service & Repair Manual

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

2006 Volvo XC90 Service & Repair Manual

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