2004 Volvo XC90 Service and Repair Manual

This factory service and repair manual for the 2004 Volvo XC90 applies to the four-door sport utility in 2.5T and T6 trims. A 2.5-liter (154 cu in) inline-five and a 2.9-liter inline-six are listed. Both are turbocharged gasoline engines with dual overhead camshafts. Procedures, specifications, torque values, wiring diagrams and diagnostics are included for the engine, fuel system, ignition, cooling, transmission, drivetrain, brakes, suspension, steering and electrical system.

Engines covered

• 2.5L inline-five (154 cu in) — DOHC, turbocharged, gasoline
• 2.9L inline-six — DOHC, turbocharged, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• 2.5T
• T6

Known issues on the 2004 XC90. Owners lodged 462 complaints about the 2004 XC90, drawn most heavily to the electrical system (158) and the power train (145), followed by the gasoline fuel system (40), the fuel and propulsion system (34) and exterior lighting (32). A crash was mentioned in 9 of them, a fire in 3 and an injury in 7. There are 6 recalls. One, covering 2,586 vehicles, involved certain 2004 XC90 SUVs whose front wheel speed sensors could send false readings, upsetting brake, engine, transmission and torque distribution control; the sensors were replaced. Certain vehicles were also recalled for outer tie rod ball joints that could deform and eventually fracture. Drivetrain diagnostics, brake wiring diagrams and steering torque values cover these areas.