Google redirecting you to your own thread while you're trying to research online? Is that a real thing? lol

I did a minor service of the angle gear while it was out, everything seemed fine with it so I just cleaned it up as it was caked in oil and gunk and refilled it with fresh clean fluid.

Yes keeping it practical is hard sometimes. I only did the turbo because it's done 200k, and while it was all out I had easy access.

Probably wouldn't do a full exhaust (DP) or lowering because it's a daily family bus. But hey if I large sum of money drops in my lap, no promises I won't change my mind ;)

When will this beast fire to life? If you were in Adelaide I would probably be around your place every second night helping out lol
Yes, it's a real annoying and fruitless thing!

Angle gear in this relatively new engine looked good to me, so happily slapped it together. Granted it had 229k km on it, but as a whole the wreck i bought seemed extremely well cared for, which may have given me an overly-optimistic confidence.. time will tell!

the best thing about pulling an engine on a car you've never worked on before is how much it informs you for later issues. I wouldn't be too worried about removing the angle gear later if needed, though it might be tight. I'd be much less inclined to change the turbo.. that damn bulkhead..

Reckon I'll have it together by end of the weekend. I keep finding new things to clean and then I feel like giving them a lick of paint, too.. but, that's my (again – optimistic!) estimation.

Welcome to the forum BTW. Nice to have another XC90 guy here, we're not well represented!

Please fly up if it's not running within 2 weeks :)
Philia_Bear;123289 wrotegive it a hard and sudden jerk (don't be slow or gentle)
Lol
Well, I put the battery terminal on last night. Lots of moaning about coolant, brake fluid, etc etc but nothing disastrous. I did discover I'd not pushed the fuel line back on far enough..

Most importantly, the S60 front seats work just fine.

I've got a few little bits on the way from ipd before I can tidy up all the loose ends, so next job is front strut rebuild.

pastry;123452 wroteMost importantly, the S60 front seats work just fine.
Wait wait hold up, are you saying seats are completely interchangeable?
Looks that way, as far as P2 seats go.

I've not tested all functions (seat heaters etc), but they move. The (lovely) plug is identical, and the bolts all line up.

Not sure which are the "best" seats, presumably there are some great comfort options in the s80 or sporty ones in the S60R.

Which would you choose?
pastry;123468 wroteLooks that way, as far as P2 seats go.

I've not tested all functions (seat heaters etc), but they move. The (lovely) plug is identical, and the bolts all line up.

Not sure which are the "best" seats, presumably there are some great comfort options in the s80 or sporty ones in the S60R.

Which would you choose?
Yea it makes sense if they are the same rail but I always assumed the XC90 seats were taller because it looks like it just sits higher, but that could be the rail height that is higher than the sedans.

The S80 seats are a lot softer, sink in to them like a nice soft leather sofa. The XC90 seats are a bit more firm but still very comfortable. I think Volvo make the best vehicle seats on the market, everyone that's been in either of my cars has commented on the seats straight away.
yes I thought the same, but yup – the mounting is simply higher up. Makes sense from a manufacturing POV.

The late model XC90 seats are probably nicer than these S60 seats, but the leather was gone and these came with the engine :)

Saab seats are also fantastic – probably both made by Lear, in fact.

pastry;123474 wrote Saab seats are also fantastic
Yes indeedy. Good to see someone else noticed. A Swedish thing?


Regarding previous posts on this thread, I notice you have an AW55-51SN auto. If you haven't done so, check the B4 servo cover. The original factory item was keech (to use a Scottish term). The updated version is far better. I had transmission issues when I got my S60, replacing the servo cover for $70 (from memory) restored my transmission to smooth shifting - had the car a couple years now without issues.

5 days later
good info @UNM. It sounds as if a model as late as 09 should be OK, the "fix" apparently is in place on cars post 04. No doubt they kept on improving it.

- - -

Saturday's progress: Still waiting on packages..

- connect the driveshaft
- Bolt up downpipe and connect midsection
- Rebuild struts and install
- new Drop links in
- Pull pass side stuck cv from box :-(
- CVs in, hubs on etc
- Brakes on, install new pads, wheels on etc
- Turbo Heat shield
- Rear struts and bushes (might wait on this)
- Spark plugs and coils
- Lights in, bumper bits on
- Bonnet and catches etc
- ipd Subframe bush inserts, install new bolts
- Oil filter *
- Fluids in!
- Brake and probably PS bleed
- Anything I've forgotten or not torqued..

* old filter housing has been absolutely torqued to death. Couldn't get it off with any of the strap-type wrenches I have so had to succumb and order a 86mm/16 flute job.

The front struts were easy enough to rebuild, but I can see them coming out again next year. The spring saga put me off doing anything for now, but the way the drivers side compressed by hand but didn't push back out is a bit of a concern.

FWIW @AshDVS (and I hope you don't mind me sharing) was able to get H&R to give him a price to build some springs. They have no on the shelf stock. That price was $899.

Ash's advice was they'd probably be able to build a spring set for a good amount less than that, but doing so means they'd need a set of base springs, which I can't supply right now. There's also the difficulty of Nivomats to consider.

Anyway, I'll probably revisit this side of things next year. The front struts are certainly easy to remove.

- - -

While I've been waiting on the last bits to arrive...

I gave the lights another go. I bought a (super)cheap polishing ball drill attachment and gave them a go over with PlastX.



They came out a fair bit better, but then I went over them with a light coat of Black Wow – which made a huge difference as a final step. It's basically an oxidation remover, thought it was worth a go. I don't have much faith it'll last but they look decent for now, and it only took 20 mins. Quick win.

Here's the front crash guard I painted the other day, too.



I used BBQ paint :flushed: – it'll definitely scratch but at least it'l be easy to touch up. Considering a coat of clear but not sure it's worth it, it'll still scratch and be that much harder to retouch.

I wrapped the oil-melted loom with SOS tape. Will have to keep an eye on whether it holds up in there. +250°c might not do it, but it seems like otherwise good stuff to work with.



Finally, trimmed a good chunk (at least +1" in the middle) out of the air box snorkel, because racebus.



This will make ALL the difference.

- - -

Is there a reason that the Iridium plugs from iPD are so cheap compared to local? They're 1/5th the price.

I got the oil filter changed, I had to put the ratchet inside a very long tube (off my jack) to get enough on it, and it kept slipping. But, it's bloody off now. Thank christ.

Those 5 min jobs eh?

No sign of my iPd packaged yet, shipped 6 Nov, so won't be finishing things up this weekend after all.
@pastry, that so's tape is that just self amalgamating tape?
Yes self fusing silicone tape
My sos taped bits near the radiator on v70 came undone! Wrapped wearing new surgical gloves, I don't rate it...
Whats the stuff that's factory and where do you get it?
We use the scotch version at work (mine site) for any temp repairs and it works well considering the harsh environment we have here.
Hah – encouraging reviews. Sounds like it may not make it, though it outwardly seems to be the same as every other tape people recommend for the engine (bay), eg F4. Roughly the same heat resistance/insulating properties etc.

I'll be keeping an eye on it.

No delivery in the end this week. Looks like Monday, so the final fixes will be in evenings next week.
7 days later
Congrats! That interior looks supple! How much of it is out of the S60?
I love the puppy in the background.
Very nice, is it still a financially viable exercise out of interest? I do like those xc90. There a D4 with a sensor fault forsale locally here for around the 2.5k mark, which would have been nice if I didn't have to many cars as it is
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