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2004 XC90 Electrical Gremlins - Ignition Switch?

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America). P2 platform.
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ChipStewart
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Joined: 26 December 2020
Year and Model: 2004
Location: Myersville, MD, USA
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2004 XC90 Electrical Gremlins - Ignition Switch?

Post by ChipStewart »

I hate electrical problems.

My 2004 XC90 was working fine when I turned off the ignition switch. When I turned it back on, the instrument cluster was dark, all the instruments were at zero (speedo, tach, temp, gas, etc.), turn signals weren't working, backup lights were out, power locks wouldn't lock or unlock, the audio system was out, mirror controls didn't work. The engine ran, windshield wipers worked (though not the fluid pump), and I had brake lights. Later, my wife drove home and all worked (at least it worked for her).

Today, I it's not working again. I noticed a few of the times the LED messages would light for a few seconds then turn off. A few of the times, the instrument cluster would light, then fade out (but still no instruments). I tried jiggling the keys, but it didn't seem to make a difference.

Any ideas? I'm thinking it's the ignition switch. Tomorrow, I'll take the case off the steering column and check voltage at the terminals.
I found this diagram:
Ignition Wiring.png
Ignition Wiring.png (37.28 KiB) Viewed 748 times
but I'm not sure how to read it. I think I should see:
∙ Key out - I should see 12v on Red-Black
∙ I (accessories) - I should see 12v on Yellow
∙ II (run) - I should see 12v on Red-Black, Blue-Red, Violet, Blue, Yellow
∙ III (start) - I should see 12v on Red-Black, Blue-Red, Yellow, Yellow-White

Is this correct? Or am I barking up the wrong tree? Any hints, tips, suggestions, or advice?
Thanks,
Chip

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June
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Post by June »

Sounds like the symptoms my 2004 S80 T6 had when the CEM was on it's way out due to water intrusion. A common problem on these P2 cars. June
My Volvo cars owned
1989 740 GLT ordered
1994 850 4door standard shift ordered
1996 960 ordered
1998 S90 ordered totalled after 3 weeks
1998 V70 GT dealer stock car
2002 S80 T6 ordered totalled
2004 S80 T6 dealer stock car and current car owned

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BlackBart
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Post by BlackBart »

I went through something very similar recently with my ‘04 XC70. I don’t know if they’re the same. But it was the DIM (“drivers information module” - or the gauge cluster assembly). The lead-free solder mandated then became brittle and many connections on the circuit board fail through heat or vibration. Many of those systems you mention are wired through that DIM.

But verify first if this is an issue with the XC90.
ex-1984 245T wagon
1994 850T5 wagon
2004 XC70 wagon BlackBetty

ChipStewart
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Post by ChipStewart »

Oh great - just the answers I was hoping I wouldn't get. So, how do I determine if the problem is the DIM and/or the CEM?

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ggleavitt
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Post by ggleavitt »

2006 V8 Ocean Race #740/800 200k, 2008 V8 Sport 183k

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