2002-2014 Volvo XC90 Alternator Replacement

This guide provides step-by-step instructions...

iFixit Library Volvo XC90 SUV - 2000-2009 Moderate 2 hours Guide 212325

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Guide overview

Before you begin

This guide provides step-by-step instructions for removing the alternator in a Volvo XC90 (2002-2014 models). This process is necessary if you are experiencing charging system failures or a noisy bearing. Estimated Time: 1.5 - 2.5 hours Difficulty: Moderate Note: Ensure the engine is cool before beginning. You will be working in a tight space near the passenger side of the engine bay.

Step 1

Disconnect the Battery

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In the cargo area, lift the floor panel to access the battery. Use a 10mm wrench to loosen the nut on the negative (black) terminal connector and pull it off the post. Secure the cable away from the terminal to prevent accidental contact while you work.

Step 2

Clear the Path

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Remove the two 10mm bolts holding the coolant expansion tank in place. Carefully lift the tank and move it toward the engine, securing it with a bungee cord if needed. Do not disconnect the hoses; you just need enough room to reach the alternator.

Step 3

Release Belt Tension

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TOOL USED ON THIS STEP T50 or T55 Torx Bit Referenced by the iFixit guide

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TOOL USED ON THIS STEP Flathead screwdriver (standard) (for releasing plastic clips — do not use with a power driver) Referenced by the iFixit guide

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Locate the serpentine belt tensioner. Using a long-handled ratchet with a T50 (or T55) Torx bit, rotate the tensioner to release pressure on the belt. Slip the belt off the alternator pulley.

Step 4

Remove Mounting Bolts

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Locate the mounting bolts securing the alternator to the engine block. Use your sockets to remove these bolts. Note that the space is tight, so a ratcheting wrench or a shallow socket may be helpful here.

Step 5

Disconnect Electrical Leads

No step image supplied by iFixit.

TOOL USED ON THIS STEP Flathead screwdriver (standard) (for releasing plastic clips — do not use with a power driver) Referenced by the iFixit guide

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TOOL USED ON THIS STEP T50 or T55 Torx Bit Referenced by the iFixit guide

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Carefully pull the alternator forward to access the back. Remove the plastic cap and unscrew the nut holding the main power lead, then depress the clip to remove the wiring harness connector.