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2005 XC90 Engine Swap

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).
Batty251
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2005 XC90 Engine Swap

Post by Batty251 » Mon May 11, 2020 8:50 am

Morning all,

I am about to swap an engine on a Volvo xc90 2005 model from a T6 4 speed to a 2.5T with the ECU and Ignition immobilizer to match the ECU as well as swapping the guts from the other key to the key already in use for the door handles and Ignition barrel so no issues of starting.



Can anyone else recommend any other kind of precaution or checks i will need to who has done this kind of swap before? Also note the reason i am swapping is because the engine in the car already is blown.



Thank you.

wanderdüne
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wanderdüne

Re: 2005 XC90 Engine Swap

Post by wanderdüne » Mon May 11, 2020 10:54 am

The 2.5T won't bolt up to the GM transmission.

Batty251
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Re: 2005 XC90 Engine Swap

Post by Batty251 » Mon May 11, 2020 11:16 am

I already have the 5 speed transmission that comes with the 2.5T.

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RickHaleParker
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Re: 2005 XC90 Engine Swap

Post by RickHaleParker » Mon May 11, 2020 1:26 pm

Batty251 wrote: ↑
Mon May 11, 2020 8:50 am
Can anyone else recommend any other kind of precaution or checks i will need to who has done this kind of swap before? Also note the reason i am swapping is because the engine in the car already is blown.
If the new engine and transmission is coming from another P2. Swap the entire subframe assembly and engine bay wiring harness. Disconnect harness under the dash, pull it out of the cowl then work it loose. But do not disconnect harness from the engine and transmission.

Disassemble front of car, headlights radiator, bumper. That will open up the front. Then you lower the subframe assembly about a decimeter and pull it straight out the front.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll 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.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger, Plant Ghent Belgium.

Batty251
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Re: 2005 XC90 Engine Swap

Post by Batty251 » Tue May 12, 2020 1:19 am

So the engine won't come out from above ? i planned to strip the engine bay and put in every piece one by one after i manage to fit in the engine and transmission. Also the reason i am stripping it isn't just clearance but to make sure every part of the engine bay is in functioning order and to clean up all the parts. I heard maybe the differential might be different maybe, dose anyone know if this is true or not?.

wanderdüne
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wanderdüne

Re: 2005 XC90 Engine Swap

Post by wanderdüne » Tue May 12, 2020 7:37 am

It seems like you would have to swap everything over, including the sway bar, axles etc. Not sure the hubs have the same splines from the T6 to the 2.5T. Also, the prop shaft might be a different length. I don't know if the angle gear is different, but would assume so. Look here: https://www.tascaparts.com/auto-parts/volvo

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RickHaleParker
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Re: 2005 XC90 Engine Swap

Post by RickHaleParker » Tue May 12, 2020 1:56 pm

Batty251 wrote: ↑
Tue May 12, 2020 1:19 am
So the engine won't come out from above ?
If you unbolt the Engine and Transmission from the Subframe you can pull up. It would be less work and easier to do as described above. That is if you are swap P2 to P2.
Batty251 wrote: ↑
Tue May 12, 2020 1:19 am
I heard maybe the differential might be different maybe, dose anyone know if this is true or not?.
What is the donor? Cannot do a comparison if we don't know what the donor is. That would be like planning a road trip when you do not know where you are.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll 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.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger, Plant Ghent Belgium.

Batty251
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Re: 2005 XC90 Engine Swap

Post by Batty251 » Wed May 13, 2020 12:59 am

Sorry for leaving out some additional details.

Donor car is a 2004 Le 2.5T Volvo XC90 AWD.

Complete car that i am swapping things into including the new trans and engine is a 2005 LE 2.9T Volvo XC90 AWD. Both are auto.


I have already summed up that the drive shaft is 4 inches short for the 2.5T which i am trying to see if getting a whole new drive shaft or make up that extra 4 inches some how as my best guess is because the 2.9T is just that little big bigger it might push the transmission further into the body making that drive shaft that 4 inches shorter, However if i mount the 2.5T in a way that would match that of the 2.9T the drive shaft might match up as their both the same holes and bolt points according to a service manual i own.

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RickHaleParker
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Re: 2005 XC90 Engine Swap

Post by RickHaleParker » Wed May 13, 2020 2:34 am

Batty251 wrote: ↑
Wed May 13, 2020 12:59 am
Sorry for leaving out some additional details.

Donor car is a 2004 Le 2.5T Volvo XC90 AWD.

Complete car that i am swapping things into including the new trans and engine is a 2005 LE 2.9T Volvo XC90 AWD. Both are auto.
2004 XC90 2.5T / 5 speed: Final - Drive Ratio 2.86 : 1
2005 XC 90 T6 / 4 speed: Final - Drive Ratio 3.69 : 1
You will need to find a rear differential with a ratio of 2.86 : 1

Wait until you get the engine/transmission swap done then see if one of the two driveshafts will fit. If nether fit, a machine shop can cut the ends off and make a driveshaft any length you need and balance it.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package, Plant: Uddevalla Sweden.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll 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.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger, Plant Ghent Belgium.

Batty251
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Re: 2005 XC90 Engine Swap

Post by Batty251 » Wed May 13, 2020 2:55 am

So the transfer case will be fine ? just gotta swap the differentials ?

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