The alternator on the Volvo XC90 sits behind the air con compressor in a tight area but can be removed without taking any major ancillaries off. A methodical approach is key.
A common failure mode on this model is the alternator pulley sleeve separating from the pulley body — this causes the drive belt to shred. The belt must also be replaced at the same time.
When You Need This Job
- Battery warning light on the dashboard
- Shredded or missing drive belt
- Squealing from the engine bay
- Car failing to start due to flat battery
- Charging voltage below 13.5V when tested
Tools You'll Need
Step-by-Step Guide
Disconnect the battery
Open the boot. Remove the black plastic cover and the metal cover over the battery — both secured with 13mm bolts. Disconnect the negative terminal first then the positive.
Remove the engine cover
Open the bonnet and pull the engine cover straight up — it lifts off its mountings.
Move the boost pipe
The boost pipe runs across the top of the engine. Unclip it and move it to the side to expose the alternator area.
Disconnect the alternator wiring
Remove the 13mm nut from the main terminal post on the rear of the alternator and pull off the cable. Unplug the spade connector.
Slacken the lower air con pump bolts
Two 10mm bolts at the bottom of the air con pump also pass through the alternator mounting. Slacken these but do not remove them fully.
Remove the two upper alternator bolts
Remove the two upper 10mm long bolts that pass through the alternator mounting. These come out fully.
Remove the side 10mm bolt
There is a single 10mm bolt going through the side of the alternator just under the power steering pulley. Remove this.
Wiggle the alternator free
With all mounting points loose the alternator can be worked out of its position from behind the air con compressor. Wiggle it towards you carefully.
Move the power steering line if needed
An 8mm bolt holds a power steering line bracket nearby. If the alternator will not clear undo this bolt and gently bend the line just enough to get clearance.
Remove the alternator
Work the alternator up and out of the engine bay.
With the engine running place a multimeter across the battery. You should see 13.8V to 14.4V. Below 13.5V means a charging fault remains.
If the belt was shredded inspect the tensioner for wear and replace it at the same time as the belt.
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