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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 »

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


IMAG0298.jpg
IMAG0299.jpg
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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RickHaleParker
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker »

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

Next: Repair the wiring damage.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
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abscate
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Re: 2005 XC90 T6 Executive Project Car.

Post by abscate »

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.
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
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bmdubya1198
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Re: 2005 XC90 T6 Executive Project Car.

Post by bmdubya1198 »

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.
'00 V70R Venetian Red/Charcoal M56 Swapped 200k
'03 S60 2.4T Silver/Black 118k
'07 XC90 V8 AWD Sport Titanium Grey/Black 174k
'91 944 Turbo Dark Green/Beige 175k
'92 245 Base White/Beige 249k
1998 V70 GLT Black/Beige 205k
'99 BMW 528i
'01 Mountaineer 5.0
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k
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RickHaleParker
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker »

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.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
User avatar
RickHaleParker
Posts: 4811
Joined: Mon May 25, 2015 2:30 pm
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Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker »

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.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
User avatar
RickHaleParker
Posts: 4811
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
Been thanked: 621 times

Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker »

Not going to get a lot done this week. April showers are overextending their welcome.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
User avatar
bmdubya1198
Posts: 4399
Joined: Tue Dec 30, 2014 10:45 am
Year and Model: 2K V70R M56
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Re: 2005 XC90 T6 Executive Project Car.

Post by bmdubya1198 »

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!
'00 V70R Venetian Red/Charcoal M56 Swapped 200k
'03 S60 2.4T Silver/Black 118k
'07 XC90 V8 AWD Sport Titanium Grey/Black 174k
'91 944 Turbo Dark Green/Beige 175k
'92 245 Base White/Beige 249k
1998 V70 GLT Black/Beige 205k
'99 BMW 528i
'01 Mountaineer 5.0
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k
User avatar
RickHaleParker
Posts: 4811
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
Been thanked: 621 times

Re: 2005 XC90 T6 Executive Project Car.

Post by RickHaleParker »

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.
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD.
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
User avatar
abscate
MVS Moderator
Posts: 22932
Joined: Sun Feb 17, 2013 5:54 pm
Year and Model: 99T5 ,99S70,2005V70
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Re: 2005 XC90 T6 Executive Project Car.

Post by abscate »

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.
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 BMW
Link to Maintenance record thread
Link To Volvo Glossary
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