Introduction
This manual provides comprehensive step-by-step maintenance and repair instructions for Volvo Diesel XC60 and XC90 models produced between 2003 and June 2013. It is designed to assist owners in understanding, caring for, and repairing their vehicles, covering a wide range of mechanical and electrical procedures.
Image: Front cover of the Haynes Owners Workshop Manual for Volvo Diesel XC60 and XC90 models, highlighting its focus on step-by-step maintenance and repair.
Image: Back cover of the manual, emphasizing "See Haynes, See How" and listing key benefits such as maintenance, servicing, fault finding, MoT test checks, fuel saving, electrics, and Haynes tips. It also shows an image of a person working on a car engine.
The manual is structured to guide users through various tasks, from routine checks to complex overhauls, with clear illustrations and detailed descriptions. It aims to empower vehicle owners to perform tasks themselves, saving time and money, and ensuring the longevity and reliability of their Volvo vehicles.
Image: An illustration of the Haynes philosophy, showing how their manuals are based on stripdown and rebuild, provide DIY-friendly techniques, and help save time by identifying issues with a fault finder.
Safety Information
Always prioritize safety when working on your vehicle. Ensure the vehicle is securely supported on jack stands, the engine is cool, and the battery is disconnected before performing any electrical work. Wear appropriate personal protective equipment, including gloves and eye protection. Refer to the manual's specific safety warnings before beginning any procedure.
Routine Maintenance and Servicing
Regular maintenance is crucial for the optimal performance and longevity of your Volvo. This section outlines routine checks and servicing procedures.
Weekly Checks
- Underbonnet check points
- Engine oil level
- Coolant level
- Brake and clutch fluid level
- Power steering fluid level
- Tyre condition and pressure
- Washer fluid level
- Electrical systems
- Wiper blades
- Battery
Lubricants and Fluids
Proper fluid levels and types are essential. Refer to the detailed specifications for engine oil, coolant, brake fluid, and other lubricants.
Tyre Pressures
Maintaining correct tyre pressures is vital for safety, fuel efficiency, and tyre longevity. Consult the manual for specific pressure recommendations for your model.
Servicing Specifications
Image: A page from the manual detailing servicing specifications, including capacities for engine oil, cooling system, fuel tank, and torque wrench settings for various components.
The manual provides detailed specifications for various components, including fluid capacities and torque settings. For example:
| Category | Item | Specification |
|---|---|---|
| Engine Oil | 2.0 litre (D5204T2/T3) | 5.9 litres |
| Cooling System | XC60 (Up to 2010) | 12.65 litres |
| Fuel Tank | XC60 | 70 litres |
| Torque Wrench Settings | Drain plug | 35 Nm (26 lbf ft) |
Repairs and Overhaul
This section covers detailed procedures for repairing and overhauling various vehicle systems.
Engine and Associated Systems
Detailed instructions for engine in-car repair procedures, engine removal and overhaul, cooling and heating systems, fuel and exhaust systems, emission control, and starting/charging systems.
Image: A page illustrating the auxiliary belt routing with diagrams and step-by-step instructions for removal and installation, including torque specifications.
Image: A page detailing the removal and refitting of the fuel gauge sender and pump unit, with multiple photographic illustrations showing the process.
Transmission
Guidance on clutch, manual transmission, automatic transmission, driveshafts, and transfer box/propeller shaft/final drive.
Brakes and Suspension
Instructions for braking system, suspension, and steering components.
Body Equipment
Procedures for bodywork and fittings, including interior components.
Image: A page illustrating the removal of various bodywork and interior fittings, such as the air vent panel and center console, with step-by-step photographic guides.
Electrical System
Information on the vehicle's electrical system, including wiring diagrams for Volvo XC60 and XC90 models.
Troubleshooting and Reference
This section provides valuable resources for diagnosing issues and general reference information.
Fault Finding
A dedicated section to help identify common problems and their potential solutions.
Glossary of Technical Terms
Definitions of technical terms used throughout the manual to ensure clarity.
General Repair Procedures
Includes guidance on jacking and vehicle support, and recommended tools and working facilities.
Specifications
Key specifications for the Volvo Diesel XC60 and XC90 models covered by this manual.
- Publisher: J H Haynes & Co Ltd
- Language: English
- ISBN-10: 1785213075
- ISBN-13: 978-1785213076
- Item Weight: 15.2 ounces
- Dimensions: 8.31 x 0.67 x 10.75 inches
Warranty and Support
This workshop manual is published by J H Haynes & Co Ltd. For inquiries regarding the content or specific technical support related to the manual, please refer to the publisher's official contact information typically found within the manual's introductory pages or their official website. This manual is intended as a guide for maintenance and repair and does not imply a warranty on vehicle parts or repairs performed by the user.
For additional resources and information, you may visit the publisher's website: www.haynes.com
