engine VOLVO XC70 2004 Service Manual

2004 VOLVO XC70
Replacing high/low beam headlight bulbs
The headlight bulbs must be replaced from the engine compartment.
CAUTION:
l Do not touch the glass on halogen bulbs with your fingers. Grease, oil o\
r any other impurities can be
carbonized onto the bulb and cause damage to the reflector.
l Be sure to use bulbs of the correct type and voltage.


Removing a defective bulb
To remove a defective low beam bulb:
l Switch off all lights and turn the ignition switch to position 0.
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pg. 128 Paint touch up
Paint touch-up
Paint damage requires immediate attention to avoid rusting. Make it a ha\
bit to check the finish regularly
- when washing the car for instance. Touch-up if necessary.
Paint repairs require special equipment and skill. Contact your Volvo re\
tailer for any extensive damage.
Minor scratches can be repaired by using Volvo touch-up paint.
NOTE: When ordering touch-up paint from your Volvo retailer, use the paint cod\
e indicated on the
model plate. The plate is located in the engine compartment.
Minor stone chips and scratches
Material:
Primer - can
Paint - touch-up bottle
Brush
Masking tape
NOTE: When touching up the car, it should be clean and dry. The surface temper\
ature should be above
60° F (15° C).
Minor scratches on the surface
If the stone chip has not penetrated down to the metal and an undamaged \
layer of paint remains, the
touch-up paint can be applied as soon as the spot has been cleaned.
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l A stiff-bristle brush and lukewarm soapy water can be used to clean the \
wiper blades. Frequent
cleaning improves visibility considerably.
l Wash off the dirt from the underside (wheel housings, fenders, etc.). \
l In areas of high industrial fallout, more frequent washing is recommende\
d.
CAUTION:
During high pressure washing, the spray mouthpiece must never be closer \
to the vehicle than 13" (30
cm). Do not spray into the locks.
Special moonroof cautions:
- Always close the moonroof and sun shade before washing your vehicle. \
- Never use abrasive cleaning agents on the moonroof.
- Never use wax on the rubber seals around the moonroof.
l When washing or steam cleaning the engine, avoid spraying water or steam\
directly on the electrical
components or toward the rear side of the engine.
l After cleaning the engine, the spark plug wells should be inspected for \
water and blown dry if
necessary.
Suitable detergents: Special car washing detergents should be used. Mix according to manufac\
turer's
instructions.
Bumpers: The bumpers are painted. Wash the bumpers with the same cleaning agent u\
sed on the rest of
the car. Never clean the bumpers with gasoline or paint thinner. Difficu\
lt spots can be removed with
denatured alcohol. To avoid scratches, do not dry the bumpers with paper\
.
WARNING!
l When the car is driven immediately after being washed, apply the brakes \
several times in order to
remove any moisture from the brake linings.
l Engine cleaning agents should not be used when the engine is warm. This \
constitutes a fire risk.


pg. 130 Washing the car, Cleaning the upholstery
Automatic washing - simple and quick
l We do NOT recommend washing your car in an automatic wash during the fir\
st six months
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pg. 132 Fuel/emissions systems
Fuel system
The fuel system continually compensates for variation in engine load, sp\
eed and temperature. A mass air
flow sensor continuously measures the inducted air and makes rapid adjus\
tments for changes in air
temperature and density, to balance fuel economy, emissions, and engine \
power requirements.
Heated oxygen sensor
This is an emission control system designed to reduce emissions and impr\
ove fuel economy. The heated
oxygen sensor monitors the composition of the exhaust gases leaving the \
engine. The exhaust gas
analysis is fed into an electronic module. This adjusts the air/fuel rat\
io to improve combustion and
reduce the three major pollutants (hydrocarbons, carbon monoxide, and o\
xides of nitrogen (NOx)) via a
three-way catalytic converter.
Crankcase ventilation
The engine is provided with positive crankcase ventilation which prevent\
s crankcase gases from being
released into the atmosphere. Instead, the crankcase gases are routed to\
the intake manifold and
cylinders.
PremAir®
On the surface of the radiator in the engine compartment, there is a spe\
cial coating called PremAir®.
PremAir® works as a catalytic converter, converting most of the ozone\
passing through the radiator into
oxygen, thereby reducing harmful ground-level ozone.
Evaporative control system
The car is equipped with an evaporative control system, which prevents g\
asoline vapor from being
released into the atmosphere.
The system consists of a fuel tank with filler pipe and cap, two rollove\
r valves, a Fill Limit Vent Valve
(FLVV), vapor vent lines, a charcoal canister, a purge line, and a pur\
ge control valve and engine
connections. In addition, there is a pressure sensor connected to the fu\
el tank and a filter-protected
Canister Close Valve (CCV) on the atmospheric side of the canister, fo\
r system diagnosis.
The gasoline vapor is channeled through the rollover valves and the FLVV\
via the vapor vent lines into
the charcoal canister, where it is stored. When the engine is started, t\
he gasoline vapor is drawn from the
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charcoal canister to the engine's air intake system and into the combust\
ion process.
NOTE:
l Overfilling the fuel tank can cause damage to the evaporative control sy\
stem.
l If the fuel filler cap is not closed tightly or if the engine is running\
when the car is refueled, the
Malfunction Indicator Lamp may indicate a fault.
l During a transitional period, a small number of service stations may sti\
ll have fuel nozzles that are not
compatible with the fuel filler neck on cars equipped with the evaporati\
ve emission control system
mandated by the U.S. Environmental Protection Agency and the California \
Air Resources Board. If you
experience difficulties in refueling your vehicle, please ask the gas st\
ation attendant for assistance.
CAUTION:
Fuel must not be siphoned from the fuel tank. This will damage the evapo\
rative control system.


pg. 133 Drive belt, Coolant
Belt check
Check the belt regularly to make sure it is in good condition and is cle\
an. A worn or dirty belt can cause
poor cooling and low alternator output as well as impair the operation o\
f the power steering and the air
conditioning unit.
NOTE: The drive belt is equipped with a self-tensioning mechanism and requires\
no adjustment
between changes.
WARNING!
The engine must not be running when this check is
performed.
Check coolant level
The cooling system must be filled with coolant and not leak to operate a\
t maximum efficiency. Check
the coolant level regularly. The level should be between the "MAX" and "\
MIN" marks on the expansion
tank. The check should be made with particular thoroughness when the eng\
ine is new or when the
cooling system has been drained.
Do not remove the filler cap other than for topping up with coolant. Fre\
quent removal may prevent
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coolant circulation between the engine and the expansion tank during eng\
ine warm up and cooling.
Changing coolant
Normally, the coolant does not need to be changed. If the system must be\
drained, consult your Volvo
retailer.
NOTE: Do not top off with water only. This reduces the rust-protective and ant\
ifreeze qualities of the
coolant and has a lower boiling point. It can also cause damage to the c\
ooling system if it should freeze.
Top off with Volvo Genuine Coolant/Antifreeze only.
CAUTION:
The cooling system must always be kept filled to the correct level. If i\
t is not kept filled, there can be
high local temperatures in the engine which could result in damage. Diff\
erent types of antifreeze/coolant
may not be mixed.
WARNING!
Never remove the radiator cap while the engine is warm. Wait until the c\
ar
cools.


pg. 134 Emissions maintenance
Periodic maintenance helps minimize emissions
Periodic maintenance will help keep your vehicle running well. Your Warr\
anty and Service Records
Information booklet provides a comprehensive periodic maintenance schedu\
le up to 150,000 miles
(240,000 km) of vehicle service. The schedule includes components that\
affect vehicle emissions. This
page describes some of the emission-related components.
Engine air filter
The engine air filter cleans particles from air entering the engine. Rep\
lace the engine air filter cartridge
with a new one every 37,500 miles (60,000 km) under normal driving con\
ditions. Replace the cartridge
more often when the vehicle is driven under dirty and dusty conditions. \
The cartridge cannot be cleaned,
and should always be replaced with a new one.
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Fuel filter
The fuel filter should be replaced at 105,000 miles (168,000 km) or at\
120,000 miles (193,000 km) for
the 2.5T engine on AWD models. The filter is replaced as a complete unit\
. Replace more frequently if
contaminated fuel is introduced into the tank, or if there is reason to \
suspect that this has occurred.
Fuel system, including filler cap, tank and lines and
connections
The ability of the fuel system to contain hydrocarbons depends upon a le\
ak-free system. Inspect fuel
lines every 30,000 miles (48,000 km). Check for proper sealing of the \
fuel filler cap which contains "O"
ring seals.
NOTE: If the fuel filler cap is not closed tightly or if the engine is running\
when the car is refueled, the
Check Engine light (Malfunction indicator) may indicate a fault. Howev\
er, your vehicle's performance
will not be affected. Use only Volvo original or approved fuel filler ca\
ps.
Timing belt
For proper functioning of the engine and its emission control systems, t\
he timing belt and belt tensioner
must be replaced every 105,000 miles (168,000 km) or at 120,000 miles \
(193,000 km) for the 2.5T
engine on AWD models. Engine damage will occur if the belt fails.
PCV system
(on turbocharged models)
The nipple in the intake manifold and the filter at the end of the PCV h\
ose in the air cleaner should be
inspected and cleaned at 105,000 miles (168,000 km) or at 120,000 mile\
s (193,000 km) for the 2.5T
engine on AWD models, and again at 150,000 miles (240,000 km).
Spark plugs
The spark plugs should be replaced every 60,000 miles (96,000 km) unde\
r normal driving conditions.
City driving or fast highway driving may necessitate replacement sooner.\
Under normal driving conditions, spark plugs require no maintenance betw\
een replacement intervals.
When installing new plugs, be sure to use the right type and to tighten \
them correctly. When changing
the plugs, clean the terminals and rubber seals. Also check that the sup\
pressor connectors are in good
condition. Cracked or damaged connectors should be replaced.
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pg. 135 Servicing

Washer fluid reservoir
The washer fluid reservoir is located in the engine compartment and hold\
s approx. 4.7 US qts. (4.5
liters).
During cold weather, the reservoir should be filled with windshield wash\
er solvent containing antifreeze.
Hoisting the car
If a garage jack is used to lift the car, the two jack attachments point\
s should be used. They are specially
reinforced to bear the weight of the car. A garage jack can also be plac\
ed under the front of the engine
support frame. Take care not to damage the splash guard under the engine\
. Ensure that the jack is
positioned so that the car cannot slide off it. Always use axle stands o\
r similar structures.
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If a two-post hoist is used to lift the car, the front and rear lift arm\
pads should be centered under the
reinforced lift plates on the inboard edge of the sill rail (see illust\
ration above).

pg. 136 Opening the hood, Engine compartment

Opening the hood
l Pull the lever located under the left side of the dash to release the ho\
od lock.
l Lift the hood slightly.
l Press up the release control located under the front edge of the hood (\
at the center) and lift.
WARNING!
Check that the hood locks properly when
closed.

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Engine compartment
1 Expansion tank - coolant
2 Power steering fluid reservoir
3 Washer fluid reservoir
4 Dipstick - engine oil
5 Radiator/cooling fan
6 Oil filler cap - engine
7 Brake fluid reservoir
8 Relay/fuse box
9 Air cleaner
10 Battery (in the cargo compartment) WARNING!
The cooling fan may start or continue to operate (for up to 6 minutes)\
after the engine has been
switched off.


pg. 137 Engine oil
Oil quality
Engine oil must meet the minimum ILSAC specification GF-2, including ACE\
A A1, API SJ, SJ/CF and
SJ/Energy Conserving.
Your Volvo has been certified to standards using ILSAC oil specification\
GF-2 5W-30. Volvo
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