Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLVO2004XC90 AWD L5-2.5L TURBO VIN 59 B5254T2REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSDIAGRAMSDIAGNOSTIC AIDSCONNECTOR, REPAIRCONNECTOR FUSE HOLDER, REPAIR
2004 Volvo XC90 AWD L5-2.5L Turbo VIN 59 B5254T2
Connector Fuse Holder, Repair
2004 Volvo XC90 AWD L5-2.5L Turbo VIN 59 B5254T2SECTION Connector Fuse Holder, Repair
Connector fuse holder, repair
Special tools: 951 2633 Terminal removal tool 951 2633 Terminal Removal Tool , 951 2639 Terminal removal tool 951 2639 Terminal Removal Tool , 951 2852 Terminal removal tool 951 2852 Terminal Removal Tool.
Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Expose the relevant fusebox.
Remove the fuses. Note the positions of the fuses.
Dismantling
Secondary lock
Releases the catches for the secondary lock.
Slide the secondary lock to one side to access the primary lock, as illustrated.
Fuse holder cargo compartment.
Fuse holder passenger compartment.
Primary lock
Use tools 951 2633 Terminal removal tool 951 2633 Terminal Removal Tool , 951 2639 Terminal removal tool 951 2639 Terminal Removal Tool to remove the primary lock, as illustrated.
Note! The relay holders can be connected and several locks may need to be adjusted at the same time.
At the same time pull the cable carefully backwards.
Alternatively use tool 951 2852 Terminal removal tool 951 2852 Terminal Removal Tool as illustrated.
Installation
Primary lock
Check that the cable terminal is undamaged.
Press the cable terminal into the housing.
Check that the cable terminal is properly locked by pulling carefully on the cable.
Secondary lock
Slide back the secondary lock.
Finishing work
Install the relays.
Note! Take care with the positioning.
Reinstall the central relay box.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.