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DIY: 2005 XC90 2.5T Fuel Filter at 82K

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).
cn90
Posts: 6667
Joined: Wed Mar 31, 2010 9:54 am
Year and Model: 2004 V70 2.5T
Location: Omaha NE
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cn90

DIY: 2005 XC90 2.5T Fuel Filter at 82K

Post by cn90 » Wed Jul 09, 2014 5:40 pm

I wrote a DIY Fuel Filter for 1998 V70 below:
http://www.matthewsvolvosite.com/forums ... 0&start=28

For 2005 XC90, it is similar except:
- No need to raise the car on ramps since the XC90 has high ground clearance.
- The quick disconnect design is a bit different

Otherwise same principles...

1. You will need:
- Gloves
- 10-mm socket
- If your fingers are weak, then long needle-nose pliers, otherwise fingers are enough to squeeze the "Quick Disconnect".
- Container to catch spilled fuel.

2. Bought fuel filter from autohausaz.com $25.
For 2003-2013 years, not sure while they list 2 different fuel filters.
I bought the PN 0450905921 made by Bosch.

3. Remove the Schrader valve cap and press the tip to release fuel.
(Same idea as car tire valve stem).

4. I sprayed some WD-40 above the 10-mm bolt the day before just in case. Rotate fuel filter to loosen the bond, then squeeze the connector to disconnect the line.

5. Cap the end of the old fuel filter to prevent spill. If you have a lawn mower, then empty the fuel into it, or you can put it back in your fuel tank as long as the ARROW is pointing forward.

6. During installation:
- Make sure the quick disconnect is FULLY SEATED, once you push it all the way in, you will hear a click.
- The Bracket holding the fuel filter only fits one way. The Bracket "Tongue" sits flush with the filter cap.
- Make sure the fuel filter ARROW points to the FRONT of the car!

7. Once done, turn the key to position II to prime the fuel pump, don't start the car yet.
Repeat this step a few times to prime fuel.

Now, start the car and check for any fuel leak.

That is it girls and boys...

XC-FuelFilter-01.JPG
XC-FuelFilter-02.JPG
XC-FuelFilter-03.JPG
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anothevolvofan
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

cn90
Posts: 6667
Joined: Wed Mar 31, 2010 9:54 am
Year and Model: 2004 V70 2.5T
Location: Omaha NE
Has thanked: 0
Been thanked: 122 times
United States of America
cn90

Re: DIY: 2005 XC90 2.5T Fuel Filter at 82K

Post by cn90 » Sun Dec 15, 2019 6:17 pm

I last replaced the XC90 fuel filter in July 2014 at 82K.
It is now Dec. 2019 and 120K (about 38K miles later).
It is rusty.

I personally think surface rust is harmless.
Any advice re surface rust? When does it start to leak due to rust?


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XC90-Fuel-Filter.jpg
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2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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