Starting System - Removal, Replacement and Installation: Other Volvo XC90 I

START SWITCH

1. In reverse order
2. Install the steering column covers.

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

REMOVING THE STARTER MOTOR

Disconnect the battery negative lead. First read, see BATTERY, DISCONNECTING .

Scheme 2

Remove

1. the intake pipe between the front cover plate and the air cleaner (ACL)
2. the connector from the mass air flow (MAF) sensor
3. the turbocharger control valve from the air cleaner (ACL) housing
4. the brake vacuum hose from the air cleaner (ACL)
5. the hose clamp between the fresh air intakes
6. mass air flow (MAF) sensor
7. the air cleaner (ACL) by pulling it straight up.

Scheme 3

Remove

1. the hose clamp on the charge air pipe on the throttle body (TB). Pull the pipe off the throttle body (TB)
2. M8 screw for the bracket in the cylinder block
3. x 2. M8 nuts in the bracket for the wiring and the engine coolant hose
4. the blade terminal connector on the solenoid
5. the nut for the positive lead
6. x 2. the M10 screws for the mounting for the starter motor
7. the starter motor.

Scheme 4

1. Slacken off the nut. Remove the cable
2. Remove the 3 screws
3. Lift the solenoid. Unhook the solenoid and the spring and hook.

Note. For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE SOLENOID

Transfer the support bracket to the new starter motor. Install the nuts loosely, they will be tightened later.

Install

1. the solenoid
2. the screws
3. the cable.

INSTALLING THE STARTER MOTOR

Install

1. the starter motor
2. x 2. the M10 screws in the transmission cover
3. x 1. M8 screw for the support bracket on the engine block. Tighten x2. The M6 nuts for the bracket on the starter motor
4. the bracket for the wiring. Use 2 M8 nuts.

Install

1. the battery positive lead
2. the blade terminal connector on the solenoid
3. the charge air pipe on the throttle body (TB)
4. the air cleaner (ACL)
5. the fresh air intake
6. the turbocharger control valve
7. the brake vacuum hose
8. the mass air flow (MAF) sensor connector.

STARTER MOTOR, REPLACING

Special tools

see 9512957

see 9512955

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Note. Lift the vehicle. See JACKING POINTS, BODY .

Scheme 5

Remove

1. the 4 screws at the suspension turrets
2. the screws of the upper engine mount on the engine
3. the upper cross stay.

REMOVING COMPONENTS

Remove

1. the battery negative cable. See: «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .
2. the expansion tank cap.

Raise the vehicle.

Scheme 6

Note. There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

Remove the 6 screws.

Lift and slide the protective plate forward.

Remove the protective plate.

INSTALLING THE PROTECTIVE PLATE

Install

1. the protective plate
2. the 6 screws; tighten.

Lower the vehicle.

REMOVING THE AIR CLEANER COVER

Remove the air cleaner cover by pulling it straight up.

Scheme 7

Remove

1. the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness
2. the connector from the mass air flow sensor.

Scheme 8

Remove

1. the 2 screws of the fresh air hose in the front plate
2. the fresh air hose
3. the hose clips of the intake manifold between the mass air flow sensor and the electronic throttle module (ETM)
4. the air cleaner by pulling it straight up.

Scheme 9

Remove

1. the connector to the brake vacuum valve
2. the vacuum hose from the vacuum pump by pressing in the quick-action lock
3. the vacuum hose from the brake vacuum valve
4. the vacuum hose from the intake manifold
5. the brake vacuum from the retainer.

Scheme 10

Detach the radiator hoses at the quick-release coupling toward the firewall.

Detach the coolant hose from the throttle body by undoing the clamp.

Bend aside the coolant hoses.

Scheme 11

Remove

1. the connector to the electronic throttle module (ETM) and the electrical distribution center
2. the protective cap from the starter motor solenoid
3. the nut of the positive leads on the starter motor solenoid
4. the positive leads
5. the control current lead from the starter motor solenoid.

Scheme 12

Remove

1. the 4 screws
2. the upper engine mount.

Scheme 13

Remove

1. the EVAP valve from the bracket
2. the line from the EVAP valve to the tank by releasing the quick-action lock
3. the hose from the intake manifold to the EVAP valve by releasing the hose clip
4. the 2 screws of the EVAP valve bracket
5. the EVAP valve bracket.

Scheme 14

Remove

1. the 3 screws of the lifting eye
2. the lifting eye.

Scheme 15

Open the hose clip and move it to the side.

Scheme 16

Remove

1. the 2 screws
2. the connection pipe. Scrap the gasket.

Scheme 17

Remove

1. the 2 screws
2. the starter motor.

Note. For tightening torques, see: TIGHTENING TORQUE .

Install

1. the starter motor.
2. the 2 screws; tighten.

INSTALLING THE COOLANT CONNECTION PIPE

Install

1. a new gasket
2. the connection pipe on the coolant hose
3. the 2 screws; tighten.

INSTALLING THE CLAMP ON THE COOLANT HOSE

Fit the clamp in its original position.

INSTALLING THE LIFTING EYE

Install

1. the lifting eye at the connection pipe
2. the 3 screws; tighten
3. the cable stem in the clip.

INSTALLING THE EVAP VALVE BRACKET

Install

1. the EVAP valve bracket
2. the 2 screws of the bracket; tighten
3. the hose from the intake manifold to the EVAP valve; secure with the clamp
4. the line to the tank on the EVAP valve; secure with the quick-action lock
5. the EVAP valve on the bracket.

INSTALLING THE UPPER ENGINE MOUNT

Install

1. the upper engine mount.
2. the 4 screws; tighten.

INSTALLING THE LEADS

Install

1. the connector to the electronic throttle module (ETM) and the electrical distribution center
2. the positive leads, x 2, on the solenoid. Tighten in accordance with: «SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS»(ref-476949-S03900293712012060500000)
3. the nut; tighten
4. the protective cover on the nut
5. the control current lead on the solenoid.

INSTALLING THE COOLANT HOSES

Install

1. the 2 coolant hoses on the connections at the firewall; secure with the quick-action lock
2. the coolant hose on the throttle body; secure with the clamp.

INSTALLING THE AIR CLEANER (ACL)

Install

1. the air cleaner on the left frame member
2. the intake hose on the throttle body; secure with the clamp
3. the connector to the mass air flow sensor.

INSTALLING VACUUM HOSES

Install

1. the vacuum hose to the vacuum pump; secure with the quick-action lock
2. the vacuum hose on the brake vacuum valve
3. the vacuum hose on the intake manifold; secure with the clamp
4. the brake vacuum valve in the retainer
5. the connector to the brake vacuum valve.

Scheme 18

Install

1. the intake manifold
2. the 2 screws.

INSTALLING THE ENGINE CONTROL MODULE (ECM) CONNECTORS

Install

1. the connectors to the engine control module (ECM); secure with quick-action lock
2. the cover over the air cleaner.

INSTALLING THE UPPER CROSS STAY

Install

1. the cross stay between the suspension turrets
2. the 4 screws in the suspension turrets; tighten
3. the screw of the cross stay mount on the upper engine mount; tighten.

CHECK

Fill with coolant using filling equipment: see 9512957 and cover: see 9512955 .

Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluid as necessary.

STARTER MOTOR

1. Disconnect the battery negative lead. See «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

Scheme 19

1. Remove the intake manifold between the front cover plate and the air cleaner(ACL) housing.
2. Applies to turbocharged engines: Remove the hose between the charge air cooler (CAC) and the electronic throttle module.

1. Disconnect the connector and the positive battery lead from the starter motor
2. Remove the 2 M10 screws securing the starter motor to the gearbox
3. Remove the starter motor.

REMOVING THE SOLENOID

1. Slacken off the nut. Remove the cable
2. Remove the solenoid screws
3. Lift the solenoid. Unhook the solenoid and the spring and hook.

Remove

1. the solenoid
2. the screws
3. the cable.

Install

1. the starter motor. Tighten to
2. x2. M10 in the gearbox
3. the battery positive lead and the nut
4. the flat pin contactor.

Only turbocharged (TC) engines: Install the hose between the charge air cooler (CAC) and the electronic throttle module (ETM).

Install

1. the fresh air intake hose
2. the battery negative lead. See «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

1. Disconnect the battery negative lead, see «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000)

Remove

1. air intake between the front cover plate and the air cleaner (ACL) housing
2. hose between the charge air cooler (CAC) and the electronic throttle module (ETM)

Unplug the connector and the battery positive lead from the starter motor.

Remove

1. the 2 M10 screws securing the starter motor to the gearbox
2. starter motor

Install

1. Torque: M10 50 Nm
2. Torque: Battery positive cable to starter solenoid 11 Nm
3. Torque: Start impulse lead 8, 5 Nm

Install the hose between the charge air cooler (CAC) and the electronic throttle module (ETM).

Install

1. the fresh air intake hose
2. the battery negative lead. See «BATTERY, DISCONNECTING»(ref-476746-S00156360512012060500000) .

Note. Removal steps in this procedure may contain installation details.

Disconnect the battery lead. See BATTERY, DISCONNECTING .

Scheme 20

Scheme 21

M10. See TIGHTENING TORQUE

Positive battery cable to starter solenoid. See TIGHTENING TORQUE

Start impulse cable. See TIGHTENING TORQUE

To install, reverse the removal procedure

see STARTER MOTOR