check engine VOLVO XC90 2004 Owner's Guide

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2004 VOLVO XC90
Paint damage requires immediate attention to avoid rusting. Make it a ha\
bit to check the finish regularly
- when washing the vehicle 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.
Color code
Make sure you have the right color. The color code number is on the data\
plate in the engine
compartment.
Minor stone chips and scratches
Material:
l Primer - can
l Paint - touch-up pen
l Brush
l Masking tape
l If the stone chip has not gone down to the bare metal and an undamaged c\
olor coat remains, you can
add paint immediately after removing dirt.
NOTE: When touching up the vehicle, it should be clean and dry. The surface te\
mperature 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.
Deep scratches
1. Place a strip of masking tape over the damaged surface. Pull the tape\
off so that any loose flakes of
paint adhere to it.
2. Thoroughly mix the primer and apply it with a small brush.
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2004 VOLVO XC90
CAUTION
The vehicle must not be driven with wheels of different dimensions or wi\
th a spare tire other than the
one that came with the vehicle. The use of different size wheels can ser\
iously damage your vehicle's
transmission.
pg. 109 Wheels and tires
Snow chains
Snow chains can be used on your Volvo with the following restrictions:
l Snow chains should be installed on front wheels only. Use only Volvo app\
roved snow chains.
l If accessory, aftermarket or "custom" tires and wheels are installed and\
are of a size different than the
original tires and wheels, chains in some cases CANNOT be used. Sufficie\
nt clearances between chains
and brakes, suspension and body components must be maintained.
l Some strap-on type chains will interfere with brake components and there\
fore CANNOT be used.
l All Wheel Drive models: Snow chains should only be installed on the front wheels. Only chains
adapted for AWD models should be used.
NOTE: Consult your Volvo retailer for additional snow chain information.
CAUTION
- Check local regulations regarding the use of snow chains before instal\
ling. Always follow the chain
manufacturer's installation instructions carefully. Install chains as ti\
ghtly as possible and retighten
periodically.
- Never exceed the chain manufacturer's specified maximum speed limit. (\
Under no circumstances
should you exceed 31 mph 50 km/h)
- Avoid bumps, holes or sharp turns when driving with snow chains.
- The handling of the vehicle can be adversely affected when driving wit\
h chains. Avoid fast or sharp
turns as well as locked wheel braking.
Snow tires, studded tires*
Tires for winter use:
Owners who live in or regularly commute through areas with sustained per\
iods of snow or icy driving
conditions are strongly advised to fit suitable winter tires to help ret\
ain the highest degree of traction.
It is important to install winter tires on all four wheels to help retai\
n traction during cornering, braking,
and accelerating. Failure to do so could reduce traction to an unsafe le\
vel or adversely affect handling.
Do not mix tires of different design as this could also negatively affec\
t overall tire road grip.
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2004 VOLVO XC90
Volvo recommends 225/70 R16 (235/65 R17 on seven-seat models with the T\
6 turbo engine) winter
tires on all four wheels.
Winter tires wear more quickly on dry roads in warm weather. They should\
be removed when the winter
driving season has ended.
Studded tires should be run-in 300 - 600 miles (500 - 1000 km) during \
which the vehicle should be
driven as smoothly as possible to give the studs the opportunity to seat\
properly in the tires. The tires
should have the same rotational direction throughout their entire lifeti\
me. In other words, if you wish to
rotate the wheels, make sure that the same wheels are always on the same\
side of the vehicle.
NOTE: Please consult state or provincial regulations restricting the use of st\
udded winter tires before
installing such tires.
* Where permitted
pg. 110 Wheels and tires
Tire pressure
Tire pressure label
Checking and correcting tire pressure
The tire pressure label is located on the inside of the fuel filler door\
.
l Check the tire pressure regularly.
l The tire pressure should be corrected only when the tires are cold.
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2004 VOLVO XC90
CAUTION
When the spare wheel is mounted on the vehicle, the retaining cable coul\
d damage the underside of
the vehicle if it is not retracted.

Returning the spare wheel to its storage compartment
NOTE: The space under the vehicle is designed to hold the special spare wheel \
only. Other fullsize
wheels will not fit in this compartment.
Returning the spare wheel to the storage compartment
1. Use the crank (turn it counterclockwise) to lower the spare wheel's\
retaining cable.
2. Pass the toggle at the end of the cable through the center hole in th\
e spare wheel. Pivot the toggle 90
degrees so that when raised, the wheel will rest on the toggle.
3. Retract the retaining cable slightly by slowly turning the crank cloc\
kwise several times.
4. Position the wheel so that it is not obstructed by components in the \
exhaust system.
5. Continue to raise the wheel by turning the crank clockwise.Raise the \
wheel a little bit at a time and
guide it around the rear axle until it is securely seated in the storage\
area.
6. When it is no longer possible to turn the crank any further, check th\
at the spare wheel is securely in
position in the storage compartment.
pg. 115 Wheels and tires
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2004 VOLVO XC90
3. Loosen the wheel bolts by exerting downward pressure on the lug wrenc\
h.
4. Remove the wheel cap (where applicable) using the lug wrench in the\
tool bag.
5. With the wheels still on the ground, use the lug wrench to loosen the\
wheel bolts 1/2 - 1 turn. Turn the
bolts counterclockwise to loosen the bolts. CAUTION
- The vehicle must not be driven with wheels of different dimensions or \
with a spare tire other than
the one that came with the vehicle. The use of different size wheels can\
seriously damage your
vehicle's transmission.
- Correct tightening torque on wheel bolts must be observed.
- The wheel bolts should never be greased or lubricated.
- Extended, chromed wheel bolts must not be used with steel rims, as the\
y make it impossible to fit
the hub caps.
WARNING!
The use of an incorrect type of wheel bolt could cause the wheel to loos\
en from the hub. Contact your
Volvo retailer if you are uncertain as to the type of wheel bolt that sh\
ould be used on your vehicle.
pg. 116 Wheels and tires

Attaching the jack
l Place the jack on the ground, under one of the attachment points (see t\
he illustration on the previous
page) and crank while simultaneously guiding the jack's attachment brac\
ket onto the attachment point
(see illustration above) The base of the jack must be flat on a level,\
firm, non-slippery surface. Before
raising the vehicle, check that the jack is still correctly positioned i\
n the attachment.
l Raise the vehicle until the wheel to be changed is lifted off the ground\
.
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2004 VOLVO XC90
2 0 0 4
VOLVO XC90
Maintenance

pg. 121 Maintenance
Volvo maintenance122
Working on your vehicle124
Engine compartment126
Oils and fluids127
Battery maintenance132
Bulbs135
Fuses143
pg. 122 Maintenance
Volvo Maintenance
Maintenance
Volvo advises you to follow the maintenance program outlined in the Warr\
anty and Service Records
Information booklet. This maintenance program contains inspections and s\
ervices necessary for the
proper function of your vehicle. The maintenance services contain severa\
l checks which require special
instruments and tools and therefore must be performed by a qualified tec\
hnician. To keep your Volvo in
top condition, specify time-tested and proven Genuine Volvo Parts and Ac\
cessories.
The Federal Clean Air Act - U.S.
The Federal Clean Air Act requires vehicle manufacturers to furnish writ\
ten instructions to the ultimate
purchaser to assure the proper servicing and function of the components \
that control emissions. These
services, which are listed in the "Warranty and Service Records Informat\
ion booklet," are not covered
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2004 VOLVO XC90
Information booklet provides a comprehensive periodic maintenance schedu\
le up to 150,000 miles
(240,000 km) of vehicle maintenance. 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.
Fuel filter
The fuel filter should be replaced at 120,000 miles (193,000 km). The \
filter is replaced as a complete
unit. Replace more frequently if contaminated fuel is introduced into th\
e tank, or if there is reason to
suspect that this has occurred.
Fuel system, including filler cap, tank, 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 vehicle is refueled,
the Check Engine light (Malfunction Indicator) may indicate a fault. H\
owever, your vehicle's
performance will not be affected. Use only Volvo original or approved fu\
el filler caps.
Timing belt
For proper functioning of the engine and emission control systems, the t\
iming belt and belt pretensioner
must be replaced every 120,000 miles (193,000 km). 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 120,000 miles (193,000 km), 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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2004 VOLVO XC90
WARNING!
The ignition system has very high voltage! The voltage in the ignition s\
ystem is dangerous!
Do not touch spark plugs, ignition cables or the ignition coil when the \
engine is running or the
ignition is switched on!
The ignition should be switched off when:
- Conducting engine tests.
- Replacing parts in the ignition system, such as spark plugs, ignition \
coil, distributor, ignition cables,
etc.
- Never try to repair any part of the SRS/SIPS/WHIPS/IC systems yourself\
. Any interference in the
system could cause malfunction and serious injury. Any work should only \
be performed by an
authorized Volvo workshop.
pg. 125 Maintenance
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
coolant circulation between the engine and the expansion tank during eng\
ine warm up and cooling.
Changing coolant
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2004 VOLVO XC90
Oil and fluids (contd)
Checking the oil level
The oil level should be checked every time the vehicle is refueled. This\
is especially important
during the period up to the first maintenance. CAUTION
Not checking the oil level regularly can result in serious engine damage\
if the oil level becomes too
low.
Park the vehicle on a level surface and wait for at least 5 minutes afte\
r the engine has been switched
off. Be sure the oil level is maintained between the upper and lower mar\
ks on the dipstick. Low oil
level can cause internal damage to the engine and overfilling can result\
in high oil consumption. The
distance between the dipstick marks represents approx. 1.6 US qt (1.5 l\
iter). The oil should preferably
be checked when cold, before the engine has been started.
NOTE: The engine must be stopped when checking the oil.
WARNING!
Do not allow oil to spill onto or come into contact with hot exhaust pip\
e
surfaces.
Adding oil (topping up)
l Add oil of the same kind as already used.
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2004 VOLVO XC90

Coolant reservoir
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 (a 50/50 mix of wate\
r and antifreeze).
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.
Check coolant regularly!
WARNING!
- Never remove the radiator cap while the engine is warm. Wait until the\
vehicle cools.
- If it is necessary to top up the coolant when the engine is warm, unsc\
rew the expansion tank cap
slowly so that the overpressure dissipates.
pg. 130 Interior
Oil and fluids (contd)
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