Question about 2004 Volvo XC90

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Trying to change spark plugs in 04 XC90

I have the cover off but unsure of how to get the plugs out

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By the cover I am going to assume that you already have removed the turbo tubing on top of the engine. If not use a 7 or 8 mm. socket to loosen all the hose clamps. then remove the inner smaller pipe that connects to the two middle silver turbo tubes. then remove the T25 torx bit that holds this tube to the larger one under it. Lastly remove the large black hose at that connects to the tube, it may be necessary to remove the two 10mm bolts for the fresh air intake tube. Now all the connections should be off the tube. With moderate force pull the pipe toward the front of the car wiggle it back and forth until it releases.

Next you will need to remove the clamps for the larger tube that runs to the outside piping down the back of the engine. Then remove the two T25 torx screws that hold the pipe to the intake manifold. You can leave the large hose that connects to the air box in place and just prop up the tubing using bungee cords or the like to hold it up and out of the way. Using the same movements pull the large tube forward and wiggle it back and forth until it releases from the silver pipes going down the back of the engine.

I hope all of that makes sense, it's a lot easier than it sounds.

Now with all of the piping out of the way you should see a plug cover that says VOLVO. It is held in place by 7ish T30 torx screws. The cover should just lift up.

Very important....

Starting at the front of the engine (the timing belt side) use a marker to number the black ignition coils from 1-6. Next make a mental picture of the routing of the wiring. It must follow the same routing or it could get pinched by the screws for the cover when reassembled.

Now, remove the 10mm bolt from each coil and pull off the coil while rotating back and forth to try to keep the coil boots from tearing. With the coils out remove the six spark plugs and discard.
I strongly recommend VOLVO spark plugs are used, I've seen allot of problems from aftermarket plugs. before installing the new plugs apply anti seize to the threads of the spark plugs. reinstall and tighten the spark plugs until their tight, they need to be tight, but don't go crazy. Reinstall the coils and bolts.

Make sure the wiring is sitting down in the valley and is not riding on the ridge or it will get pinched and you'll have to pull it all back apart. Reassemble all the pieces in reverse order, just make sure that when you reinstall the turbo piping that they fully seat on the silver pipes on the back of the engine. Usually just push and wiggle them back on.

Now there are two to three vacuum lines on the large turbo tube that go to the air box. Make sure they get plugged back in if they have come loose, most of the time they are fine, but sometimes they fall off.

Well, good luck. Just take your time and be thorough, it's not that hard it's just a little time consuming.

Hope this helps.

Posted on Feb 28, 2009

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