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

Servicing - A/t (4T65AWD) Volvo XC90 I

Step-by-step instructions on "Servicing - A/t (4T65AWD)" for Volvo XC90 I (2002–2006). Pick an article — removal, installation, adjustment and diagnostics with illustrations.

214subsections

214articles

137illustrations

OIL LEVEL, CHECKING

1 article

• OIL LEVEL, CHECKING

CHECKING THE OIL LEVEL

1 article

• CHECKING THE OIL LEVEL

PREPARATIONS

1 article

• PREPARATIONS

OIL LEVEL / TEMPERATURE

1 article

• OIL LEVEL / TEMPERATURE 1

Checking The Position Of The Gear Selector Lever

1 article

• Checking The Position Of The Gear Selector Lever 1

Check The Gearshifts In Manual Mode

1 article

• Check The Gearshifts In Manual Mode 1

Installing The Air Cleaner (ACL) Housing

1 article

• Installing The Air Cleaner (ACL) Housing

Check

1 article

• Check

NOTE WHEN DISCONNECTING/CONNECTING THE BATTERY LEAD

1 article

• NOTE WHEN DISCONNECTING/CONNECTING THE BATTERY LEAD

Engine

1 article

• Engine

PINION SEAL BEVEL GEAR, REPLACING

1 article

• PINION SEAL BEVEL GEAR, REPLACING

Preparatory Work

1 article

• Preparatory Work

Removing The Nuts For The Bevel Gear Flange

1 article

• Removing The Nuts For The Bevel Gear Flange 1

Removing The Flange

1 article

• Removing The Flange 1

Removing The Seal

1 article

• Removing The Seal 1

Installing The Seal

1 article

• Installing The Seal 1

Installing The Flange On The Pinion

1 article

• Installing The Flange On The Pinion

Installing A New Nut In The Carrier

1 article

• Installing A New Nut In The Carrier 1

Filling And Checking Oil

1 article

• Filling And Checking Oil

Finishing

1 article

• Finishing

Install The New Boot

1 article

• Install The New Boot 1

Reinstall The Panel On The Center Console

1 article

• Reinstall The Panel On The Center Console 1

Installing The Gear Selector Knob And Boot

1 article

• Installing The Gear Selector Knob And Boot

Removing The Center Console

1 article

• Removing The Center Console

Removing The Solenoid

1 article

• Removing The Solenoid 1

Installing The Solenoid

1 article

• Installing The Solenoid

Installing The Center Console

1 article

• Installing The Center Console

REMOVING CENTER TUNNEL CONSOLE

1 article

• REMOVING CENTER TUNNEL CONSOLE 5

TOP PANEL GEARTRONIC, REPLACING

1 article

• TOP PANEL GEARTRONIC, REPLACING

Removing The Top Panel

1 article

• Removing The Top Panel 1

Removing The Gear Selector Knob

1 article

• Removing The Gear Selector Knob

Removing And Transferring The Boot From The Top Panel

1 article

• Removing And Transferring The Boot From The Top Panel 1

Installing The Boot

1 article

• Installing The Boot

Installing The Top Panel

1 article

• Installing The Top Panel

Installing The Gear Selector Knob And Lock Bracket

1 article

• Installing The Gear Selector Knob And Lock Bracket

CABLE KEY INTERLOCK, REPLACING

1 article

• CABLE KEY INTERLOCK, REPLACING 2

Removing The Gear Selector Cable From The Ignition Switch

1 article

• Removing The Gear Selector Cable From The Ignition Switch 1

Removing The Gear Selector Cable From The Steering Column

1 article

• Removing The Gear Selector Cable From The Steering Column 1

Installing The Gearbox Cable

1 article

• Installing The Gearbox Cable

Initial Setting Of The Key Lock Cable (Adjusting)

1 article

• Initial Setting Of The Key Lock Cable (Adjusting)

Finishing Work

1 article

• Finishing Work

Detaching The Boot And Removing The Gear Selector Knob

1 article

• Detaching The Boot And Removing The Gear Selector Knob

Installing Gear Selector Knob And Boot

1 article

• Installing Gear Selector Knob And Boot

GEAR SELECTOR CABLES, REPLACING

1 article

• GEAR SELECTOR CABLES, REPLACING

Removing The Air Cleaner (ACL) Housing

1 article

• Removing The Air Cleaner (ACL) Housing 1

Removing The Gear Selector Cable And Ball Joint

1 article

• Removing The Gear Selector Cable And Ball Joint 1

Removing The Left Front Wheel

1 article

• Removing The Left Front Wheel 1

Removing Side Panels

1 article

• Removing Side Panels 1

Removing The Gear Selector Cable

1 article

• Removing The Gear Selector Cable 1

Removing The Gear Selector Cable At The Firewall

1 article

• Removing The Gear Selector Cable At The Firewall 1

Installing The Gear Selector Cable From The Inside Of The Passenger Compartment

1 article

• Installing The Gear Selector Cable From The Inside Of The Passenger Compartment

Locate The Grommet On The Studs

1 article

• Locate The Grommet On The Studs

Feeding In The Gear Selector Cable From The Inside

1 article

• Feeding In The Gear Selector Cable From The Inside

Installing The Gear Selector Cable On The Gear Selector

1 article

• Installing The Gear Selector Cable On The Gear Selector

Installing The Gear Selector Cable On The Transmission

1 article

• Installing The Gear Selector Cable On The Transmission

Removing The Boot From The Gear Selector Knob

1 article

• Removing The Boot From The Gear Selector Knob

Removing The Lock Bracket From The Gear Selector Knob

1 article

• Removing The Lock Bracket From The Gear Selector Knob 2

Installing The Gear Selector Knob

1 article

• Installing The Gear Selector Knob 2

Installing The Lock Bracket On The Gear Selector Knob

1 article

• Installing The Lock Bracket On The Gear Selector Knob 2

Removing Centre Tunnel Console

1 article

• Removing Centre Tunnel Console 2

Installing The Locking Sleeve For The Boot

1 article

• Installing The Locking Sleeve For The Boot 1

Installing The Centre Tunnel Console

1 article

• Installing The Centre Tunnel Console

CONTROL SYSTEM/VALVE HOUSING, REMOVING

1 article

• CONTROL SYSTEM/VALVE HOUSING, REMOVING

Removing The Side Cover

1 article

• Removing The Side Cover

Preparations For Removing The Valve Housing

1 article

• Preparations For Removing The Valve Housing

Air Vent Housing

1 article

• Air Vent Housing 1

Control System Housing

1 article

• Control System Housing 1

Removing The Screws For The Valve Housing And Pressure Sensor

1 article

• Removing The Screws For The Valve Housing And Pressure Sensor 1

Removing And Separating The Valve Housing

1 article

• Removing And Separating The Valve Housing 1

Distribution Plate

1 article

• Distribution Plate 1

Checking And Reinstalling The Balls In The Valve Housing

1 article

• Checking And Reinstalling The Balls In The Valve Housing 1

Check The Sealing Of The Balls Against The Distribution Plate

1 article

• Check The Sealing Of The Balls Against The Distribution Plate

Check The Sealing Of The Balls Against The Control System Housing

1 article

• Check The Sealing Of The Balls Against The Control System Housing

Installing New Solenoids On The New Valve Housing

1 article

• Installing New Solenoids On The New Valve Housing 1

CONTROL SYSTEM / VALVE HOUSING, INSTALLING

1 article

• CONTROL SYSTEM / VALVE HOUSING, INSTALLING

Transferring The Balls To The New Valve Housing

1 article

• Transferring The Balls To The New Valve Housing

Transferring

1 article

• Transferring

Checking The Balls In The Valve Housing

1 article

• Checking The Balls In The Valve Housing 1

Installing New Gaskets

1 article

• Installing New Gaskets 3

Replacing The Seal On The Pump Shaft

1 article

• Replacing The Seal On The Pump Shaft 1

Installing The Balls For The Control System Housing

1 article

• Installing The Balls For The Control System Housing 1

Installing The Valve Housing

1 article

• Installing The Valve Housing

Installing The Oil Pump

1 article

• Installing The Oil Pump

Installing The Side Cover

1 article

• Installing The Side Cover

COVER DIFFERENTIAL, REPLACING

1 article

• COVER DIFFERENTIAL, REPLACING

Removing The Bevel Gear/Chain Housing

1 article

• Removing The Bevel Gear/Chain Housing

Disconnecting The Pipe From The Turbocharger (TC)

1 article

• Disconnecting The Pipe From The Turbocharger (TC) 1

Removing The Bracket For The Bevel Gear/Chain Housing

1 article

• Removing The Bracket For The Bevel Gear/Chain Housing 1

Removing The Transmission Output Speed Sensor From The Cover On The Transmission

1 article

• Removing The Transmission Output Speed Sensor From The Cover On The Transmission 1

Checking The Bearing Surface On The Differential

1 article

• Checking The Bearing Surface On The Differential 1

Installing The Spacer Washer And Throw-Out Bearing

1 article

• Installing The Spacer Washer And Throw-Out Bearing 1

Installing The Differential Housing Cover

1 article

• Installing The Differential Housing Cover 1

Installing The Transmission Output Speed Sensor

1 article

• Installing The Transmission Output Speed Sensor

Installing The Bracket For The Bevel Gear/Chain Housing

1 article

• Installing The Bracket For The Bevel Gear/Chain Housing

Installing The Pipe On The Turbocharger (TC)

1 article

• Installing The Pipe On The Turbocharger (TC)

Installing The Bevel Gear / Chain Housing

1 article

• Installing The Bevel Gear / Chain Housing

Filling The Cooling System

1 article

• Filling The Cooling System

TRANSMISSION OIL / OIL FILTER, REPLACING

1 article

• TRANSMISSION OIL / OIL FILTER, REPLACING

Install The Oil Filter

1 article

• Install The Oil Filter

Install The Oil Pan

1 article

• Install The Oil Pan 1

Install A Plastic Hose On The Oil Return Line

1 article

• Install A Plastic Hose On The Oil Return Line 1

Fill The Transmission With Oil. There are two different methods. Method 1

1 article

• Fill The Transmission With Oil. There are two different methods. Method 1 1

Fill The Transmission With Oil. Method 2

1 article

• Fill The Transmission With Oil. Method 2 1

When Filling (Select Method 1 Or 2)

1 article

• When Filling (Select Method 1 Or 2) 1

Install The Oil Return Line On The Transmission

1 article

• Install The Oil Return Line On The Transmission

Lower The Car

1 article

• Lower The Car

Pour The Rest Of The Oil Into The Transmission

1 article

• Pour The Rest Of The Oil Into The Transmission 1

Check The Oil Level

1 article

• Check The Oil Level

Check That There Is No Oil Leakage At The Pipe Couplings Or Oil Pan Install The Splashguard Under The Engine

1 article

• Check That There Is No Oil Leakage At The Pipe Couplings Or Oil Pan Install The Splashguard Under The Engine

Removing The Side Cover From The Transmission

1 article

• Removing The Side Cover From The Transmission

Removing The Oil Pump

1 article

• Removing The Oil Pump 1

Removing The Oil Pump From The Pump Shaft

1 article

• Removing The Oil Pump From The Pump Shaft 1

Installing The Side Cover On The Transmission

1 article

• Installing The Side Cover On The Transmission

GASKET / PISTON ACCUMULATOR, REPLACING

1 article

• GASKET / PISTON ACCUMULATOR, REPLACING

Removing The Accumulator Housing From The Transmission

1 article

• Removing The Accumulator Housing From The Transmission 2

Removing The Pistons From The Accumulator Housing

1 article

• Removing The Pistons From The Accumulator Housing 1

Installing New Pistons For The Accumulator Housing

1 article

• Installing New Pistons For The Accumulator Housing 1

Installing The Accumulator Housing On The Transmission

1 article

• Installing The Accumulator Housing On The Transmission

GASKET/O RING SERVO CYLINDER, REPLACING

1 article

• GASKET/O RING SERVO CYLINDER, REPLACING

Removing The Servo Cylinder (2-1)

1 article

• Removing The Servo Cylinder (2-1) 2

Replacing The Gasket, O-Ring And Strainer

1 article

• Replacing The Gasket, O-Ring And Strainer 1

Installing The Servo Cylinder On The Transmission

1 article

• Installing The Servo Cylinder On The Transmission 1

SIDE COVER TRANSMISSION, REMOVING

1 article

• SIDE COVER TRANSMISSION, REMOVING

Disconnecting The Battery Lead

1 article

• Disconnecting The Battery Lead

Removing Engine Compartment Components

1 article

• Removing Engine Compartment Components 1

Removing The Coolant Hose From The Passenger Compartment Heater

1 article

• Removing The Coolant Hose From The Passenger Compartment Heater

Disconnecting The Charge Air Pipe

1 article

• Disconnecting The Charge Air Pipe 1

Removing The Connector From The Transmission

1 article

• Removing The Connector From The Transmission 1

Installing The Lifting Beams And Lifting Hooks On The Engine Lifting Lugs

1 article

• Installing The Lifting Beams And Lifting Hooks On The Engine Lifting Lugs 1

Removing The Lower Steering Shaft From The Steering Shaft Joint

1 article

• Removing The Lower Steering Shaft From The Steering Shaft Joint 2

Removing Both The Front Wheels

1 article

• Removing Both The Front Wheels 1

Removing Components From The Sub-Frame

1 article

• Removing Components From The Sub-Frame 1

For Cars With Fuel Powered Parking Heaters

1 article

• For Cars With Fuel Powered Parking Heaters

Removing The Cross Members From The Body

1 article

• Removing The Cross Members From The Body 1

Removing The Front Cross Member

1 article

• Removing The Front Cross Member 1

Removing Screws And Nuts From The Engine Pad And Engine Stabilizer Brace

1 article

• Removing Screws And Nuts From The Engine Pad And Engine Stabilizer Brace 1

Detaching The Power Steering Line

1 article

• Detaching The Power Steering Line 1

Removing Front Suspension Components On Both Sides

1 article

• Removing Front Suspension Components On Both Sides 2

Disconnecting The Ball Joint Pinion From The Control Arm (Both Sides)

1 article

• Disconnecting The Ball Joint Pinion From The Control Arm (Both Sides) 1

Unhooks The Control Arm From The Ball Joint Pinion (Both Sides)

1 article

• Unhooks The Control Arm From The Ball Joint Pinion (Both Sides) 1

Removing The Drive Shaft From The Wheel Hub (Both Sides)

1 article

• Removing The Drive Shaft From The Wheel Hub (Both Sides) 1

Removing The Drive Shaft From The Transmission (Left-Hand Side)

1 article

• Removing The Drive Shaft From The Transmission (Left-Hand Side) 1

Removing The Fender Liner And Support Plate

1 article

• Removing The Fender Liner And Support Plate 1

Removing The Screws From The Sub-Frame Support Plates (Both Sides)

1 article

• Removing The Screws From The Sub-Frame Support Plates (Both Sides) 1

Lowering The Sub-Frame

1 article

• Lowering The Sub-Frame 1

Removing The Oil Pipe From The Transmission

1 article

• Removing The Oil Pipe From The Transmission 1

Lowering The Engine And Transmission

1 article

• Lowering The Engine And Transmission 2

SIDE COVER TRANSMISSION, INSTALLING

1 article

• SIDE COVER TRANSMISSION, INSTALLING

Checking The Gasket For The Side Cover

1 article

• Checking The Gasket For The Side Cover 1

Installing Cover

1 article

• Installing Cover 1

Lifting The Engine And Transmission To The Horizontal Position

1 article

• Lifting The Engine And Transmission To The Horizontal Position

Installing Oil Pipes

1 article

• Installing Oil Pipes

Installing The Left Drive Shaft On The Transmission And The Wheel Spindle

1 article

• Installing The Left Drive Shaft On The Transmission And The Wheel Spindle 1

Installing The Sub-Frame On The Bodywork

1 article

• Installing The Sub-Frame On The Bodywork 1

Installing The Drive Shaft On The Wheel Hub

1 article

• Installing The Drive Shaft On The Wheel Hub 1

Installing The Cross Members On The Bodywork

1 article

• Installing The Cross Members On The Bodywork

Installing The Front Mounting For The Exhaust Pipe And The Cross Member

1 article

• Installing The Front Mounting For The Exhaust Pipe And The Cross Member

Installing The Power Steering Line

1 article

• Installing The Power Steering Line

Installing The Screws For The Engine Pads And Engine Stabilizer Brace

1 article

• Installing The Screws For The Engine Pads And Engine Stabilizer Brace

Installing Front Suspension Components (Both Sides)

1 article

• Installing Front Suspension Components (Both Sides)

Installing Components For The Fender Liner

1 article

• Installing Components For The Fender Liner 1

Installing The Cable Duct

1 article

• Installing The Cable Duct

Removing The Lifting Beams

1 article

• Removing The Lifting Beams

Installing The Lower Steering Shaft On The Steering Shaft Joint

1 article

• Installing The Lower Steering Shaft On The Steering Shaft Joint 1

Installing Steering Shaft/Firewall Boot

1 article

• Installing Steering Shaft/Firewall Boot 1

Installing The Coolant Hose

1 article

• Installing The Coolant Hose

Installing The Connector On The Transmission

1 article

• Installing The Connector On The Transmission

Installing Engine Compartment Components

1 article

• Installing Engine Compartment Components

Method 1

1 article

• Method 1 1

Method 2

1 article

• Method 2 1

Installing The Battery Lead

1 article

• Installing The Battery Lead

Check That There Is No Oil Leakage At

1 article

• Check That There Is No Oil Leakage At

Installing The Front Splash Guard

1 article

• Installing The Front Splash Guard

SOLENOID LOCK-UP FUNCTION, REPLACING

1 article

• SOLENOID LOCK-UP FUNCTION, REPLACING

Removing The Lock-Up Solenoid

1 article

• Removing The Lock-Up Solenoid 1

Installing The Lock-Up Solenoid

1 article

• Installing The Lock-Up Solenoid

Removing The Line Pressure Solenoid

1 article

• Removing The Line Pressure Solenoid

Removing Solenoid S1

1 article

• Removing Solenoid S1 1

Installing Solenoid S1

1 article

• Installing Solenoid S1

Removing Solenoid S2

1 article

• Removing Solenoid S2

Installing Solenoid S2

1 article

• Installing Solenoid S2

Disconnecting The Pressure Sensor

1 article

• Disconnecting The Pressure Sensor 1

Installing The Pressure Sensor

1 article

• Installing The Pressure Sensor

SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, REPLACING

1 article

• SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, REPLACING

Removing The Right Drive Shaft

1 article

• Removing The Right Drive Shaft 1

Disconnecting The Steering Gear From The Engine Pad

1 article

• Disconnecting The Steering Gear From The Engine Pad 1

Removing The Chain Housing Bracket

1 article

• Removing The Chain Housing Bracket 1

Removing The Screws For The Bevel Gear/Chain Housing

1 article

• Removing The Screws For The Bevel Gear/Chain Housing 1

Removing The Servo Cylinder Cover

1 article

• Removing The Servo Cylinder Cover 1

Removing The Piston From The Transmission

1 article

• Removing The Piston From The Transmission 1

Replacing The Piston With O-Ring And Sealing Ring

1 article

• Replacing The Piston With O-Ring And Sealing Ring 1

SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, INSTALLING

1 article

• SEALING RING AND PISTON WITH O-RING FOR FRONT SERVO, INSTALLING

Installing The Piston In The Transmission

1 article

• Installing The Piston In The Transmission

Installing The Servo Cylinder Cover

1 article

• Installing The Servo Cylinder Cover

Installing The Bracket

1 article

• Installing The Bracket

Installing The Steering Gear To The Engine Pad

1 article

• Installing The Steering Gear To The Engine Pad

Installing The Drive Shaft

1 article

• Installing The Drive Shaft 1

SUB-FRAME FRONT, REPLACING

1 article

• SUB-FRAME FRONT, REPLACING

Preparation

1 article

• Preparation

Removing The Clamp For The Servo Pressure Hose

1 article

• Removing The Clamp For The Servo Pressure Hose 1

Removing The Right Engine Mounting

1 article

• Removing The Right Engine Mounting 3

Removing The Splash Guard Under Engine

1 article

• Removing The Splash Guard Under Engine 1

Removing The Skid Plate

1 article

• Removing The Skid Plate 2

Exposing The Sub-Frame

1 article

• Exposing The Sub-Frame 5

Removing The Drive Shaft

1 article

• Removing The Drive Shaft 5

Removing The Sub-Frame

1 article

• Removing The Sub-Frame 1

Transferring Components

1 article

• Transferring Components 1

Installing The Sub-Frame

1 article

• Installing The Sub-Frame 1

Installing Removed Components

1 article

• Installing Removed Components

Installing The Skid Plate

1 article

• Installing The Skid Plate

Installing The Right-Hand Engine Mounting

1 article

• Installing The Right-Hand Engine Mounting

Installing The Clamp For The Servo Pressure Hose

1 article

• Installing The Clamp For The Servo Pressure Hose

Removing Lifting Tools

1 article

• Removing Lifting Tools

Installing Wheels

1 article

• Installing Wheels