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2005 XC90 T6 Executive Project Car.

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
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RickHaleParker
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Wed May 15, 2019 10:34 am

Sunroof Drain hose pulled out of Drain Valve.
Drain Valve soften and split.


IMAG0298.jpg
IMAG0299.jpg


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

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RickHaleParker
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Wed May 15, 2019 1:59 pm

Raided the local PnP. Got a Drain Valve and A pillar cover in good condition. Sunroof drain problem solved.

Next: Repair the wiring damage.


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

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abscate
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abscate

Re: 2005 XC90 T6 Executive Project Car.

Post by abscate » Wed May 15, 2019 2:17 pm

Indeed
Today tried to trouble shoot ECM-432B without doing any wire tracing.
Translation - frustrate oneself needlessly and proclaim the car has electrical demons.

Electrical is the system that best responds to logic and a systematic approach.


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bmdubya1198
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Re: 2005 XC90 T6 Executive Project Car.

Post by bmdubya1198 » Wed May 15, 2019 6:45 pm

Yuck... that connector is definitely an issue!
abscate wrote:
Wed May 15, 2019 2:17 pm
Electrical is the system that best responds to logic and a systematic approach.
Agreed. Guessing isn't going to solve anything... although it sounds much easier.


1998 V70 GLT Black/Beige 191k
2000 V70R Venetian Red/Charcoal M56 Swapped 188k
2001 S60 2.4T Black/Black 230k
2007 XC90 V8 AWD Sport Titanium Grey/Black 151k
1998 S90- Silver/Gray 207k
1995 850 collection of parts... crushed... still have parts, PM if interested!
1988 744 Turbo M46 Beige Metallic/Beige 188k- Still kicking myself for getting rid of this one

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RickHaleParker
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Thu May 16, 2019 1:01 am

abscate wrote:
Wed May 15, 2019 2:17 pm
Translation - frustrate oneself needlessly and proclaim the car has electrical demons.
bmdubya1198 wrote:
Wed May 15, 2019 6:45 pm
Agreed. Guessing isn't going to solve anything... although it sounds much easier.
People who cannot do comparative analysis might resort to religions belief or guessing. I am not one of them people.


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

User avatar
RickHaleParker
Posts: 2739
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
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RickHaleParker

Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Sat May 18, 2019 6:45 pm

ECM-432B Leak detection module, valve - single missing is history.

Solder Seal Heat Shrink Butt Wire Splices turned out to be the way to go in that tight space. It was a lot easier because, once it got started the Shrink tube held it all together until the solder melted. Also it is a lot easier to work hot air from a heat gun in a tight space. Most people have a heat gun stored in the bathroom, you know it as a blow dryer.

The Solder Seal Heat Shrink Butt Wire Splices worked OK, way better the crimp connectors, but next time I use them I am going to put a drop of Liquid Rosin on the joint for better solder flow.



Next get the engine running right.
IMAG0304.jpg
Last edited by RickHaleParker on Mon May 20, 2019 10:51 am, edited 3 times in total.


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

User avatar
RickHaleParker
Posts: 2739
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
Been thanked: 303 times
United States of America
RickHaleParker

Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Mon May 20, 2019 10:26 am

Not going to get a lot done this week. April showers are overextending their welcome.


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

User avatar
bmdubya1198
Posts: 2857
Joined: Tue Dec 30, 2014 10:45 am
Year and Model: '98 V70 GLT
Location: Charlotte, NC
Has thanked: 25 times
Been thanked: 68 times
United States of America
bmdubya1198

Re: 2005 XC90 T6 Executive Project Car.

Post by bmdubya1198 » Mon May 20, 2019 10:45 am

Ugh I hate rain. It's supposed to get into the high 90s by Memorial Day around here, not looking forward to that! The high 80s we have now is miserable enough!


1998 V70 GLT Black/Beige 191k
2000 V70R Venetian Red/Charcoal M56 Swapped 188k
2001 S60 2.4T Black/Black 230k
2007 XC90 V8 AWD Sport Titanium Grey/Black 151k
1998 S90- Silver/Gray 207k
1995 850 collection of parts... crushed... still have parts, PM if interested!
1988 744 Turbo M46 Beige Metallic/Beige 188k- Still kicking myself for getting rid of this one

User avatar
RickHaleParker
Posts: 2739
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
Been thanked: 303 times
United States of America
RickHaleParker

Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker » Sun May 26, 2019 7:15 pm

ECM-3100: Misfire, at least one cylinder, Start up.
ECM-3220: Misfire cylinder 2, Start up.
ECM-3240: Misfire cylinder 4, Start up.
ECM-3260: Misfire cylinder 6, Start up.

Engine has no power.
Throttle position does follow the accelerator pedal between minimum and maximum.
Catalytic converter does overheat at high RPMs but flow at tail pipe feels strong.
Cylinders 2,4 & 6 are misfiring when the engine is running. No misfires on 1,3 & 5.


Air, Possible sources:
1. Air leakage
2. Blocked crankcase ventilation.
3. Damaged VVT-unit.

Fails glove test.
Fails intake smoke test: Seals leaking on Air filter to Turbos pipe (VPN 30636760), both sides.
Fails Intake Vacuum test: No Vacuum, +3 PSI pressure with engine at 4000 rpm.
Charge tube pressure test @ 4000 RPM: Jumps to +7 PSI then falls to +3 PSI and holds.

Smoke test: Seals leaking at the red arrows.
IMAG0307.jpg


Anybody know where to source the seals for VPN 30636760?
IMAG0313.jpg


Fuel, Possible sources:
1. Low fuel level
2. Poor fuel quality (summer fuel in winter)
3. Contaminated or incorrect fuel
4. Blocked / leaking injector
5. Faulty fuel pressure
6. Engine does not reach normal operating temperature between several cold starts

Fuel pressure 380 Kpa, right at spec.


Fire, Possible sources:
1. Water in the spark plug wells
2. Damaged spark plug
3. Uneven compression

Spark plug wells are dry.
Spark plugs are pretty much gone.
Compression Good: (1) 122 PSI, (2) 119 PSI, (3) 122 PSI, (4) 122 PSI, (5) 119 PSI, (6) 122 PSI.
IMAG0309.jpg
IMAG0311.jpg



Kind of on the fence on which way to go next. The misfiring on 2,4, & 6 can explain the overheating Catalytic Converter but, 3 PSI in the intake and charge pipe at high RPMs ~~~
Option 1, Drop some new plugs in, put it back together an do a back pressure test on the exhaust system.
Option 2, Forge ahead on the engine. Plugs, PCV. Timing Belt service and possibly a new set of injectors. Deal with the exhaust system later if it turns out it is restricted.


Platform: P80 1998 C70, B5234T3, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.

Platform: X40 (Nedcar) 2003 S40, B4204T3, AW55-50/51SN, Siemens EMS 2000. Plant: Born Netherlands.

Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0, Plant Torslanda Sweden.
----------------------------------------------------------------
1997 S90, B6304S, AW30-42, Bosch Motronic 4.4 - Sold

User avatar
abscate
MVS Moderator
Posts: 17324
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
Location: NYC, ALBANY NY
Has thanked: 185 times
Been thanked: 560 times
Trinidad & Tobago
abscate

Re: 2005 XC90 T6 Executive Project Car.

Post by abscate » Mon May 27, 2019 2:36 pm

I think you have to load it to get good charge reading, not just rev, unless you have a hack?

Definitely new plugs, I think those are bigger than the Del Water Gap. 50-60 thou?

Misfiring will trigger the ECU to limit boost , too.


1 SWMBO for 30 years
2 Volvos
3 VWs
4 Careers
5 cats/dogs/gears
6 Perfect Ladies in waiting
7 Drivers
8 Boats- with a big pointy metal thing on top

1999 V70 T5M 56 2005 V70 NA M56 VWs BMW

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