2003 xc90 battery keeps dying

[difflock54]

My wifes little runabout (not a Volvo) had exact same type of problems 2 weeks back.
Had no start problems but fired up straight away with jumper leads off my V40.
Battery only 13 months old with no prior issues and when tested the first time along with the alternator the system showed as all ok and normal.All cables/connections were checked and ok.
Went for a long 120km highway drive to allow a good charge up and stopped at shops near home on way back.
Ten minute stopped only and it was dead again on the starter but lights/accessories still worked.
Called the battery service centre and they came straight away to retest. This time battery only showing 10.6volts.
Jump started her and straight back to service centre where alternator again tested as ok so it was a dead cell in the battery, probably intermittent internal shorting.
Fitted a new battery and all has been well since.

[gooster007]

Thanks for the additional input difflock54! I hope that fixes your problem!
I had already changed my battery, so I don't think I'll be as lucky.
So it happened again. I jumped it with a battery pack I bought JUST for this beast. it ran for a bit, but again died. Luckily I was at a friends house, so it wasn't too bad. I called AAA to give me a flatbed ride home, since I was not sure I would make it home, and it was late. Well after 90minutes of waiting, I canceled the call and forded my way home w/o issue.
FUSES: I went ahead and replaced ALL the smaller ATM fuses (in side of dashboard, in engine bay, and in back cargo area). So far so good, but now I can't drive it. I had scheduled inspection for a Friday. Well on Wednesday, my wife was waiting to make a left turn when a big truck passed coming from the other direction and kicked up a stone. This chipped the windshield and also caused an instant crack about 6-8" long. The sun has since grown it to almost 2ft! I have read in other forums that the ECM\ECU (basically the "tray" that holds the fuses) goes bad. I think my next step is to find out why my fuses are getting overheated. This is going to take testing solenoids\relays\coils\etc. Check out these guys BTW for good info on these procedures...

(YOUTUBE) Automotive Repair: Testing ECM Inputs and Outputs

[gooster007]

ITS ALIVE!!!!

[gooster007]

Well, I really thought it the culprit was the Engine Control Module since its what sends the signal to the alternator to charge. Turns out it was also part alternator.

ECM REPLACEMENT: I sent the ECM out to XeMODeX to be rebuilt for $300 + S/H. By the way, express shipping is TOTALLY worth it. FedEx picked up my package at 4:30pm Tuesday, delivered it to XeMODex by 10am next day in Canada. The great staff worked they're magic, replaced a bad component or two, re-flowed contacts, put bigger heat-sinks on, and warrantied it "for life" (kinda like Volvo, eh?). I then had it back Thursday at Lunch time! WOW!!! Install/removal is about 5 minutes each way. Very easy.

ALTERNATOR SWAP: Not so easy... lol! On Monday, I ordered rebuilt BOSCH Alter. from PartsGeek.com BIG MISTAKE!!! I quickly got order confirm. But no tracking info even 24 hours after order. I tried calling several times from land lines, cell phones etc., only to get a clear hold music, then a garbled voice after 5 minutes (like a baad connection - thus using multi phones). I tried trackign online - no luck. I even called FedEx to see if theyt even HAD a pkg destined for me - again nothing. So I sent an email request ticket to their customer support per their website and phone instructions. I STILL have not received any response 4 days later. So I called up my ol buddies at FCPEuro. They had the part, negotiated the price down a bit for me, and shipped it out second day air on Wednesday as I stated I needed it for this weekend. Well Thursday I get an email stating it FINALLY SHIPPED!!!! 2-day would make it Monday! I called them up again, and they apologized for not gettign it out Wednesday as promised, so THEY UPPED THE SHIPPING OF A 20LB PKG TO NEXT DAY AT NO CHARGE!!! I thanked the man, and promised never to leave them again for [most] parts.

ALTERNATOR INSTALL: This took several hours (a lot of talking with the neighbors, and letting my 7yr old in on the action removing some bolts etc.), but afterwards it was worth it. I could NOT have done it without Andrew Peng's awesome write up!
http://andrewpeng.net/cars/2006-volvo-x ... eplacement
My biggest helper was to remove the bolts & nut that hold the fuel lines that run right under the alternator. Getting it in is easier than getting it out. Also make sure the cap that covers the positive cable on the ALT fits the new nut. If not, then use the old nut. Remove the Heat-shield on the back of the alt to make it easier.

LMK if you have any questions. I need to go for a swim after yesterdays alternator replacement marathon. Thanks for reading!


My heart broke though when the alternator failed completely about a week later....

[gooster007]

Please disregard the last line... hahaha..... the alternator did not fail a week later. I meant to have that line after the ECM reinstall. About a week after putting the repaired ECM from XeMODeX in, the Alternator completely failed, thus sparking my Alternator Replacement project. Sorry about that.

[gooster007]

Well its nearing the end of August, and I have not had a single issue with electrical since the new 180a alternator went in. If anybody needs help or has questions regarding XC90 keeps dying or alternator replacement in general. I'd be happy to help. Also my VIDA DICE came in for anyone in the Pittsburgh PA Region.

Thanks again,