engine VOLVO XC90 2004 Repair Manual

2004 VOLVO XC90
pg. 132 Maintenance
Battery Maintenance
The battery in your vehicle is located under the floor of the cargo comp\
artment.
Driving habits and conditions, climate, the number of starts, etc. all a\
ffect the service life and function of
the battery. In order for your battery to perform satisfactorily, keep t\
he following in mind:
l Check the fluid level in each cell in the battery every 24 months or eve\
ry 15,000* miles (24,000 km),
whichever is sooner. The fluid should be at the level shown in the illus\
tration above (A)**.
l Use a screw driver to open the caps and a flashlight to inspect the leve\
l.
l If necessary, add distilled water. The level should never be above the i\
ndicator (A**).
l The fluid level should be checked if the battery has been recharged.
l After inspection, be sure the cap over each battery cell is securely in \
place.
l Check that the battery cables are correctly connected and properly tight\
ened. Route ventilation hose
through opening in floor (see
page 133)
l Never disconnect the battery when the engine is running, for example whe\
n changing the battery.
l The battery should be disconnected from the vehicle when a battery charg\
er is used directly on the
battery.
l However, if the battery is being charged via the connecting points in th\
e engine compartment (see
page 100), the battery must be connected.
* More frequently in warm climates.
** The level indicator inside the battery could be designed in various w\
ays. See illustration.
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2004 VOLVO XC90
Replacing fuses
If an electrical component fails to function, it is possible that a fuse\
has blown.
The fuse boxes are located in three different places:
A - Relays/fuse box in the engine compartment
B - Fuse box in the passenger compartment
C - Relays/fuse box in the cargo compartment.
A label on the inside of each cover indicates the amperage and the elect\
rical components that are
connected to each fuse.
The easiest way to see if a fuse is blown is to remove it. Pull the fuse\
straight out. If a fuse is difficult to
remove, you will find a special fuse removal tool in the passenger compa\
rtment fuse box. From the side,
examine the curved metal wire (see next page) to see if it is broken. \
If so, put in a new fuse of the same
color and amperage (written on the fuse). Spare fuses are stored in the fuse box in the \
engine
compartment and the passenger compartment. If fuses burn out repeatedly,\
have the electrical system
inspected by an authorized Volvo retailer.
WARNING!
Never use fuses with higher amperage than those stated on the following \
pages. Doing so could
overload the vehicle's electrical system.
pg. 144 Maintenance
Fuses (contd)
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2004 VOLVO XC90

A-To open, press the plastice catches on the rear side of the fuse box c\
over and lift.
Relay/Fuse box in the engine compartment
When replacing fuses, be sure to replace a blown fuse with a new one of \
the same color and amperage
(written on the fuse).
Fuses in the engine compartment
No. Amperage
1. Accessories 25
2. -
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2004 VOLVO XC90
3. -
4. Oxygen sensors 20
5. Crankcase ventilation heater, solenoid valves 10
6. Mass air flow sensor, engine control module, injectors 15
7. -
8. A/C compressor, accelerator pedal position sensor, E-box
fan 10
9. Horn 15
10. Tailgate washer 10
11. A/C compressor, ignition coils 20
12. Brake light contact 5
13. Windshield wipers 25
14. ABS/DSTC 30
15. Headlight washers 25
16. Windshield washers 15
17. Low beam, right 10
18. Low beam, left 10
19. ABS/DSTC 30
20. High beam, left 15
21. High beam, right 15
22. Starter motor 25
23. Engine control module, system relay 5
24. -
pg. 145 Maintenance
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2004 VOLVO XC90
Fuses in the passenger compartment
Fuses are located inside the access panel on the end face of the dashboa\
rd. There are also a number of
spare fuses. No. Amperage
1. Blower - climate system 30
2. Audio amplifier 30
3. Power driver's seat 30
4. Power passenger's seat (option) 30
5. Driver's door - central locking, power windows, door mirror 25
6. Front passenger's door - central locking, power windows, door mirror \
25
7. Rear side doors - power windows, child safety locks 30
8. -
9. -
10. Power passenger's seat 5
11. Electric socket 12V 15
12. Ignition switch (30-feed), central electronic module, starter moto\
r relay,
SRS, antenna ring, engine management system 10
13. -
14. Electronic module (ceiling), courtesy lighting (ceiling) 10
15. -
16. Speed-sensitive power steering (T6 only), vacuum pump 15
17. ABS/DSTC 5
18. Heated driver's seat (option) 15
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2004 VOLVO XC90
2 0 0 4
VOLVO XC90
Specifications

pg. 147 Specifications
Label information148
Dimensions and weights149
Capacities151
Lubricants152
Cooling system152
Suspension152
Electrical system154
Bulbs155
Engine specifications, Transmission156
All specifications are subject to change without prior notice.
pg. 148 Specifications
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2004 VOLVO XC90
Label information
1 Vehicle Emission Control Information
Your Volvo is designed to meet all applicable emission standards, as evi\
denced by the certification label
on the underside of the hood. For further information regarding these re\
gulations, please consult your
Volvo retailer.
2 Vacuum hose routing
(underside of hood)
3 Loads and Tire Pressures
(on inside of fuel filler door)
4 Model plate
Vehicle Identification Number (VIN). Codes for color and upholstery, e\
tc. The plate is located in the
engine compartment, on the inside of the left front fender.
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2004 VOLVO XC90
Fuel tank 19 US gals. (72 liters), minimum octane requirement - AKI 87 (RON
91) - unleaded fuel (See also page 82)
Engine oil
B5254T2 6.1 US qts. (5.8 liters)
B6294T 7.1 US qts. (6.7 liters)
Transmission oil
Automatic (AW 55-50 5- speed) 7.9 US qts. (7.5 liters)
Automatic (GM 4-speed) 7.9 US qts. (7.5 liters)
Miscellaneous
Power steering 0.9 US qts. (0.9 liters)
Windshield washer reservoir 6.9 US qts. (6.5 liters)
Brake fluid 0.63 US qts. (0.6 liters)
Air conditioning system Front - 2.2 lb. (1 kg), Rear (option) 2.9 lb. (1.3 kg) R 134a
WARNING!
When adding accessories, equipment, luggage and other cargo to your vehi\
cle, the total capacity
weight must not be exceeded.
pg. 152 Specifications
Lubricants
Engine oil
Meeting minimum ILSAC specification GF-2, including ACEA A1, API SJ, SJ/\
CF and SJ/ Energy
Conserving.
Oil additives must not be used.
Transmission
Oil grade:
4-speed automatic (on models with 6-cylinder turbo engines):
Dexron III G (Volvo P/N 1161521).
5-speed automatic (on models with 5-cylinder turbo engines):
Volvo synthetic transmission oil Volvo P/N 1161540.
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2004 VOLVO XC90
l Keep your engine properly tuned. Certain engine malfunctions, particular\
ly involving the electrical,
fuel or distributor ignition systems, may cause unusually high three-way\
catalytic converter
temperatures. Do not continue to operate your vehicle if you detect engi\
ne misfire, noticeable loss of
power or other unusual operating conditions, such as engine overheating \
or backfiring. A properly tuned
engine will help avoid malfunctions that could damage the three-way cata\
lytic converter.
l Do not park your vehicle over combustible materials, such as grass or le\
aves, which can come into
contact with the hot exhaust system and cause such materials to ignite u\
nder certain wind and weather
conditions.
l Excessive starter cranking (in excess of one minute), or an intermitte\
ntly firing or flooded engine can
cause three-way catalytic converter or exhaust system overheating.
l Remember that tampering or unauthorized modifications to the engine, the\
Electronic Control
Module, or the vehicle may be illegal and can cause three-way catalytic \
converter or exhaust system
overheating. This includes:
- Altering fuel injection setting or components.
- Altering emission system components or location or removing components\
.
- Repeated use of leaded fuel.
NOTE: Unleaded fuel is required for vehicles with three-way catalytic converte\
rs.
pg. 154 Specifications
Electrical system

12-volt system with voltage controlled generator. Single wire system in \
which the chassis and engine
block are used as conductors, grounded on the chassis.
Battery 2.5TT6
Voltage 12 V12 V
Cold start capacity
(CCA) 520 A
600 A
Reserve capacity (RC) 90
min 115 min
If you must replace your battery, be sure to replace it with a battery o\
f the same cold start capacity and
reserve capacity as the original (See the decal on the battery). Generator max. current 140 A*160 A
Starter motor, power 1.4 kW 1.7 kW
Spark plugs P/N272313-8 or equivalent
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2004 VOLVO XC90
Gap 0.028-0.032 in.0.7-0.8
mm
Tightening torque 22 ft. lbs. (30 Nm)
Firing order 1-2-4-5-3 1-5-3-6-2-4
* Models equipped with the optional rear A/C unit have 160 A generators.\

pg. 155 Specifications
Bulbs
Bulbs OutputSocket
Low beam 55 W H7
High beam 55 W H7
Bi-Xenon headlights
(option) 35 W
D2R
Fog lights, front 55 W H 1
Parking lights, front 5W5 W2.1x9.5d
Turn signals, front 21 W PY (amber)
Turn signals, rear 21 W PY (amber)
Parking lights, rear 5 W BA15
Brake light 21 W BA15
Back up lights 21 W BA15
Fog light, left rear 5 W BA15
License plate lighting 5 W W 2.1x9.5 d
Courtesy lighting, front 5 W SV 8.5
Cargo compartment lighting 5 W SV 8.5
Glove compartment lighting 3 W BA 9
Vanity mirror 1.2 W SV 5.5
pg. 156 Specifications
Engine specifications, Transmission
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