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 RELAY BOX, REPAIR
2004 Volvo XC90 AWD L5-2.5L Turbo VIN 59 B5254T2
Connector Relay Box, Repair
2004 Volvo XC90 AWD L5-2.5L Turbo VIN 59 B5254T2SECTION Connector Relay Box, Repair
Connector relay box, 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 relay box.
Remove the relevant relays, noting their position.
Dismantling
Secondary lock
Release the relevant secondary lock by adjusting the locks with an electrician's screwdriver, as illustrated.
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.
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,
The secondary lock
Press the secondary lock into place.
Finishing work
Install the relays.
Note! Take care with the positioning.
Install the relevant 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.