Manual sections

Wiring diagrams

• Abbreviations
• Accessory Drive Belts
• Airbag
• Alarm and Parking Assistance - Installation Instructions, Accessories
• Anti-Lock/traction Control
• Automatic HVAC System
• Automatic Trans
• Axle Shafts
• Basic Trouble Shooting
• Blowers, Superchargers & Turbochargers
• Body Electrical
• Brakes
• Brakes Control Systems
• Bumpers, Mudflaps and Exterior Panels - Installation Instructions, Accessories
• Cabin Air Filter
• Cables and Fuses - Removal, Replacement and Installation
• Charging System
• Check Lists
• Climate Units - Removal, Replacement and Installation
• Clutches Manual & Hydraulic
• Collision/avoidance
• Communication Devices
• Cooling Fan
• Cooling System (Mechanical)
• Cruise Control Systems
• Diagnostic Connector Locations
• Differentials & Drive Axles
• Door Locks & Anti-Theft Systems
• Drive Cycles
• Driveline/axles
• Driveshaft & Universal Joints
• DTC Index
• Electrical Component Locations
• Electrical Components - Design and Function
• Electrical Systems - System Overview
• Electronic Modules - Design and Function
• Electronic Steering
• Emission Applications
• Engine
• Engine - Overhaul Instructions
• Engine - Removal, Replacement and Installation - 1 of 2
• Engine - Removal, Replacement and Installation - 2 of 2
• Engine Block and Fuel Driven Heater - Installation Instructions
• Engine Control Systems
• Engine Performance
• Entertainment Systems
• Exhaust
• Exterior Body Panels
• Exterior Lights
• Exterior/interior Trim
• Frames, Subframes & Crossmembers
• Fuel System
• Fuses & Circuit Breakers
• Gauges & Instrument Panels
• General Servicing - All Makes
• Headlights
• Heated Glass/defoggers
• Hoist/jack
• Identification
• Ignition System
• Intake and Exhaust System - Removal, Replacement and Installation
• Interior Panels, Seats and Upholstery - Removal, Replacement and Installation
• Locking Hubs
• Lubrication System
• Manual & Power Steering
• Mechanical
• Mechanical - Hydraulic
• Media, Communication and Navigation - Installation Instructions, Accessories - 1 of 2
• Media, Communication and Navigation - Installation Instructions, Accessories - 2 of 2
• Media, Communication and Navigation - Removal, Replacement & Installation
• Metric Conversions
• Mirrors
• Miscellaneous Electrical - Design and Function
• Mode 6
• Navigation System
• Oem General Information
• Paint/coatings
• Parking Brake System
• Passive Restraints
• Procedures
• Rear Axle, Drive Shafts - Removal, Replacement and Installation
• Reset Procedures
• Restraints
• Seats
• Servicing - A/t (4T65AWD)
• Servicing - A/t (AW50/51 Awd)
• Specifications
• Starter
• Steering
• Steering - Removal, Replacement and Installation
• Steering Column
• Steering Column Switches
• Stowage and Towing - Installation Instructions, Accessories
• Sun Roof/t-Top/convertible Top
• Suspension Front
• Suspension Rear
• System
• Testing & Diagnostics
• Timing Belt
• Towing Systems
• Traction Control Disable
• Transmission
• Transmission - Removal, Replacement and Installation
• Transmission Control Systems
• Wheel & Tire System
• Wheel Alignment
• Wheel Hubs
• Windows
• Wiper/washer Systems

Repair manual

Engine - Overhaul Instructions Volvo XC90 I

Step-by-step instructions on "Engine - Overhaul Instructions" for Volvo XC90 I (2002–2006). Pick an article — removal, installation, adjustment and diagnostics with illustrations.

88subsections

88articles

229illustrations

BALANCE SHAFT BEARING

1 article

• BALANCE SHAFT BEARING 21

INSTALLING FRONT CRANKSHAFT SEAL

1 article

• INSTALLING FRONT CRANKSHAFT SEAL 2

INSTALLING THE TIMING GEAR PULLEY FOR THE CAMSHAFTS

1 article

• INSTALLING THE TIMING GEAR PULLEY FOR THE CAMSHAFTS 3

FINISHING

1 article

• FINISHING 6

CHECKING THE MARKINGS AND BELT TENSION

1 article

• CHECKING THE MARKINGS AND BELT TENSION

OIL PUMP / CRANKSHAFT SEAL, FRONT, REPLACING

1 article

• OIL PUMP / CRANKSHAFT SEAL, FRONT, REPLACING

BELT DRIVE, DISMANTLING

1 article

• BELT DRIVE, DISMANTLING 1

REMOVING THE OIL PUMP

1 article

• REMOVING THE OIL PUMP 3

REMOVING THE THERMOSTAT AND THERMOSTAT HOUSING

1 article

• REMOVING THE THERMOSTAT AND THERMOSTAT HOUSING 1

INSTALLING THE CRANKSHAFT TIMING GEAR PULLEY

1 article

• INSTALLING THE CRANKSHAFT TIMING GEAR PULLEY

INSTALLING THE IDLER PULLEY AND BELT TENSIONER

1 article

• INSTALLING THE IDLER PULLEY AND BELT TENSIONER

CHECKING AND ADJUSTING THE VARIABLE VALVE TIMING UNIT

1 article

• CHECKING AND ADJUSTING THE VARIABLE VALVE TIMING UNIT 1

DISMANTLING THE BELT DRIVE

1 article

• DISMANTLING THE BELT DRIVE

ALIGNING THE ENGINE ACCORDING TO THE MARKING

1 article

• ALIGNING THE ENGINE ACCORDING TO THE MARKING

REMOVING THE BELT TENSIONER AND IDLER PULLEY

1 article

• REMOVING THE BELT TENSIONER AND IDLER PULLEY 4

CHECKING THE OPENING FUNCTION OF THE THERMOSTAT

1 article

• CHECKING THE OPENING FUNCTION OF THE THERMOSTAT

INSTALLING THE WATER PUMP

1 article

• INSTALLING THE WATER PUMP 5

DISMANTLING THE BELT TRANSMISSION

1 article

• DISMANTLING THE BELT TRANSMISSION

REMOVING THE CRANKSHAFT PULLEY

1 article

• REMOVING THE CRANKSHAFT PULLEY 1

CHECKING THE OIL PUMP

1 article

• CHECKING THE OIL PUMP

REMOVING THE COOLANT PUMP / TIMING BELT COVER

1 article

• REMOVING THE COOLANT PUMP / TIMING BELT COVER 5

CAULKING

1 article

• CAULKING

CLEANING

1 article

• CLEANING 3

SELECTING BEARINGS

1 article

• SELECTING BEARINGS 11

REMOVING THE SCREWED JOINT FROM THE INTERMEDIATE SECTION

1 article

• REMOVING THE SCREWED JOINT FROM THE INTERMEDIATE SECTION 1

REMOVING THE PISTON COOLING VALVE AND NOZZLES

1 article

• REMOVING THE PISTON COOLING VALVE AND NOZZLES 1

NEW CONNECTING ROD

1 article

• NEW CONNECTING ROD 1

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

1 article

• CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

INSTALLING THE PISTON COOLING VALVE AND NOZZLES

1 article

• INSTALLING THE PISTON COOLING VALVE AND NOZZLES 1

CLASSIFICATION OF MAIN BEARINGS

1 article

• CLASSIFICATION OF MAIN BEARINGS 1

APPLYING LIQUID GASKET

1 article

• APPLYING LIQUID GASKET

MARKING THE CONNECTING ROD (WHERE APPLICABLE)

1 article

• MARKING THE CONNECTING ROD (WHERE APPLICABLE) 1

INSTALLING PISTON RINGS

1 article

• INSTALLING PISTON RINGS

INSTALLING THE PISTONS IN THE CYLINDER BORES

1 article

• INSTALLING THE PISTONS IN THE CYLINDER BORES

INSTALLING THE OIL PUMP SUCTION PIPE

1 article

• INSTALLING THE OIL PUMP SUCTION PIPE

INSTALLING THE SUMP

1 article

• INSTALLING THE SUMP 2

INSTALLING THE REAR CRANKSHAFT SEAL

1 article

• INSTALLING THE REAR CRANKSHAFT SEAL

REMOVING THE SUCTION PIPE FROM THE OIL PUMP

1 article

• REMOVING THE SUCTION PIPE FROM THE OIL PUMP

CHECKING MARKINGS

1 article

• CHECKING MARKINGS 1

REMOVING THE PISTONS FROM THE CYLINDER BLOCK

1 article

• REMOVING THE PISTONS FROM THE CYLINDER BLOCK 5

SEPARATING THE INTERMEDIATE SECTION FROM THE CYLINDER BLOCK

1 article

• SEPARATING THE INTERMEDIATE SECTION FROM THE CYLINDER BLOCK 1

MEASURING THE CRANKSHAFT

1 article

• MEASURING THE CRANKSHAFT

CHECK THE OUT-OF-TRUE OF THE CRANKSHAFT

1 article

• CHECK THE OUT-OF-TRUE OF THE CRANKSHAFT

REMOVING THE PISTON RINGS

1 article

• REMOVING THE PISTON RINGS

CHECKING PISTON RING AXIAL CLEARANCE

1 article

• CHECKING PISTON RING AXIAL CLEARANCE 1

CALCULATING THE RUNNING CLEARANCE OF THE PISTON

1 article

• CALCULATING THE RUNNING CLEARANCE OF THE PISTON

CHECKING THE BEARING RECESS IN THE CONNECTING ROD BIG END

1 article

• CHECKING THE BEARING RECESS IN THE CONNECTING ROD BIG END

CRANK MECHANISM, DISMANTLING

1 article

• CRANK MECHANISM, DISMANTLING 7

RECONDITIONING

1 article

• RECONDITIONING 22

MEASURING THE CYLINDER BORE

1 article

• MEASURING THE CYLINDER BORE 2

CLASSIFICATION MARKING

1 article

• CLASSIFICATION MARKING

CHECKING FOR WEAR

1 article

• CHECKING FOR WEAR

INSTALLING THE CYLINDER HEAD

1 article

• INSTALLING THE CYLINDER HEAD

INSTALLING TAPPETS AND CAMSHAFTS

1 article

• INSTALLING TAPPETS AND CAMSHAFTS 5

MEASURING AND RECONDITIONING THE CYLINDER HEAD

1 article

• MEASURING AND RECONDITIONING THE CYLINDER HEAD 4

CHECKING FOR WEAR IN THE VALVE GUIDES

1 article

• CHECKING FOR WEAR IN THE VALVE GUIDES

CHECKING THE HEIGHT OF THE VALVE STEMS

1 article

• CHECKING THE HEIGHT OF THE VALVE STEMS 3

REMOVING THE CYLINDER HEAD

1 article

• REMOVING THE CYLINDER HEAD 4

REMOVING TAPPETS

1 article

• REMOVING TAPPETS

REMOVING VALVES

1 article

• REMOVING VALVES

REMOVING VALVE STEM SEALS

1 article

• REMOVING VALVE STEM SEALS

CHECKING THE CYLINDER HEAD

1 article

• CHECKING THE CYLINDER HEAD

INSTALLING VALVE STEM SEALS

1 article

• INSTALLING VALVE STEM SEALS

INSTALLING THE VALVE / VALVE SPRINGS

1 article

• INSTALLING THE VALVE / VALVE SPRINGS

CYLINDER HEAD, INSTALLING

1 article

• CYLINDER HEAD, INSTALLING

ALIGNING THE CRANKSHAFT

1 article

• ALIGNING THE CRANKSHAFT

INSTALLING VALVE LIFTERS AND CAMSHAFTS

1 article

• INSTALLING VALVE LIFTERS AND CAMSHAFTS 2

INSTALLING THE REAR CAMSHAFT SEAL

1 article

• INSTALLING THE REAR CAMSHAFT SEAL

SECURING THE CAMSHAFTS

1 article

• SECURING THE CAMSHAFTS

CYLINDER HEAD, REMOVING

1 article

• CYLINDER HEAD, REMOVING 1

REMOVING THE CAMSHAFT COVER

1 article

• REMOVING THE CAMSHAFT COVER 5

CHECKING THE VERTICAL POSITION OF THE VALVE STEM

1 article

• CHECKING THE VERTICAL POSITION OF THE VALVE STEM

INSTALLING VALVE SPRINGS

1 article

• INSTALLING VALVE SPRINGS 12

PREPARATORY WORK

1 article

• PREPARATORY WORK 2

ENGINE BLOCK, INSTALLING COMPONENTS

1 article

• ENGINE BLOCK, INSTALLING COMPONENTS

INSTALLING ENGINE BLOCK COMPONENTS

1 article

• INSTALLING ENGINE BLOCK COMPONENTS 2

CRANKSHAFT SEAL REAR, REPLACING

1 article

• CRANKSHAFT SEAL REAR, REPLACING 4

ENGINE BODY, EXPOSING

1 article

• ENGINE BODY, EXPOSING

REMOVING THE GEARBOX

1 article

• REMOVING THE GEARBOX 3

PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING

1 article

• PRESSURE PLATE / CLUTCH DRIVEN PLATE, REPLACING 7

SEALING MICRO-ENCLOSED SCREWS

1 article

• SEALING MICRO-ENCLOSED SCREWS 5

EXPOSING THE ENGINE BODY

1 article

• EXPOSING THE ENGINE BODY

REMOVING THE TRANSMISSION

1 article

• REMOVING THE TRANSMISSION

REMOVING THE FLYWHEEL AND CARRIER PLATE

1 article

• REMOVING THE FLYWHEEL AND CARRIER PLATE 14

PLACE THE ENGINE IN A STAND

1 article

• PLACE THE ENGINE IN A STAND

EXPOSING THE ENGINE

1 article

• EXPOSING THE ENGINE

GEAR HOUSING, RECONDITIONING

1 article

• GEAR HOUSING, RECONDITIONING 42

REAR END ACCESSORY DRIVE

1 article

• REAR END ACCESSORY DRIVE