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    1. #1
      Junior Member CDN XC90's Avatar
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      CDN XC90's build thread

      Starting a thread to document the progress on my new to me Volvo XC90.

      My folks asked me in late September if I wanted their low mileage (56k kms) 2006 2.5T AWD XC90. All original, unadulterated, and driven by a little old lady (my mom ).





      I said sure and made preparations to sell my modded Subaru Legacy 2.5i wagon.




      I didn't get any reasonable hits so removed most of the bolt-ons and reverted to selling it closer to stock at a reduced price. It was a busy time as we were also expecting our second child at the end of October.

      Car was in British Columbia and we live in Ontario. I shopped around for transport and found the best option on UShip. Transporter allowed loading the vehicle interior with additional households goods which added significant value for us.

      Last edited by CDN XC90; 11-26-2017 at 08:12 AM. Reason: layout, typos

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    3. #2
      Junior Member CDN XC90's Avatar
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      Pics to follow as I can get them uploaded.

      To register an out of province vehicle in Ontario, you need a safety inspection certificate. The front brake pads were thin and the rotors were suspect (thick lips at outer edge plus corrosion on vanes) so I went ahead and bought fresh rotors and pads all around from a local vendor. Wagner MX-series semi-metallic Thermoquiet pads and coated rotors. Flushed brake lines with fresh DOT4 fluid. I'll switch to Motul 5.1 when I get my braided lines (planned).



      For insurance purposes as well as peace of mind, I swapped out the literally like new Bridgestone Dueler H/L Alenza Plus in the stock 235/65/17 size for some Falken Eurowinter HS449 snow tires. The Bridgestone tires are for sale if anyone local to me is interested...

      Last edited by CDN XC90; 11-26-2017 at 09:08 AM.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    4. #3
      Junior Member CDN XC90's Avatar
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      Yesterday, I washed and spent about 45 mins trying to clean the brake dust residue off the wheels. The Sonax wasn't enough even after agitating with a brush so broke out the Eagle One and a scotchbrite green pad. Probably as good as it gets for what are now dedicated winters.




      Sport grille and LEDs for low and high beams, H11 and H7 respectively. I'm running this brand in my KTM with good results after trying a similar one that was weak by comparison. These have a CREE XHP50 emitter that is pretty wicked bright.







      I tried them with the included glass lenses that were supposed to reduce the Kelvin to 4300 but they were too yellow so back to stock 6000k (no filter).



      Cutoff pretty good in halogen reflectors although I had to readjust the aim downwards quite a bit.


      Last edited by CDN XC90; 11-26-2017 at 10:38 AM.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

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    6. #4
      Junior Member CDN XC90's Avatar
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      Planned:

      HEICO lowering springs
      HEICO Bilsteins
      IPD HD spring seats
      IPD strut brace brackets
      IPD subframe bushing inserts
      IPD sways
      Meyle HD endlinks
      Drawtite trailer hitch
      Custom Yonaka exhaust (prototype)
      Fast FC05 20" wheels with Conti DWS06 255/45/20
      Aftermarket subwoofer
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    7. #5
      Junior Member CDN XC90's Avatar
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      Debadged and stickers!

      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    8. #6
      Member V50R's Avatar
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      AWESOME Progress and a great find! I have A V8 and I love it and I think the only other XC90 I would own would be the 2.5T. Been looking for one as a toy car but havent found any decent ones around here, most are destroyed by careless owners.

      I am quite interested in your LED upgrade, I think I may just do this to our 2008 V8 and see how it pans out.
      2010 XC90 V8 Executive R-Design Exhaust (MINE)
      2008 XC90 V8 Executive Edition, fully loaded, 177k, STOCK (MOMS)
      2008 XC90 V8 Executive Edition, NAV, DVDs, 152k, STOCk (DADS)
      2005 XC90 V8 Black, VB replaced, (SIBLINGs) S60R Brake Swaped
      2007 XC90 V8 Dark Grey BASE MODEL 85k STOCK
      2013 GOLF Sportwagen GTD 6spd. Malone S2+ tuned 192fwhp/343fwtq.
      2013 Audi A4 Quattro. APR S2, DP, IC, E85 Tune 330hp/410tq.
      SOLD:: 2006 V50 T5 AWD AW55, 320mm FR Brake upgrade, Elevate Intake, OBX Exhaust_

    9. #7
      Junior Member CDN XC90's Avatar
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      Aeroquip quick drain plug. Kept the female coupler from my old Subaru.

      My folks changed the oil regularly but only dino juice... Looks like varnish?

      Switched to Castrol 0w40 for the winter.

      Last edited by CDN XC90; 12-11-2017 at 07:33 AM. Reason: layout

    10. #8
      Junior Member CDN XC90's Avatar
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      13.8l/100 for almost all highway trip back from picking up parts in NY State. 120km/hr on cruise control. Hoping to see if that will improve.

      Car has fresh oil, new HEICO (bmc) air filter and 91 octane. Tires are 32psi all round currently as usually running unladen (235/65/17). I may try upping the tire pressure a bit to see if it makes a difference. Placard shows 36/39 F/R if loaded.s-l400.jpg
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    11. #9
      Member oneofakind's Avatar
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      Quote Originally Posted by CDN XC90 View Post
      13.8l/100 for almost all highway trip back from picking up parts in NY State. 120km/hr on cruise control. Hoping to see if that will improve.

      Car has fresh oil, new HEICO (bmc) air filter and 91 octane. Tires are 32psi all round currently as usually running unladen (235/65/17). I may try upping the tire pressure a bit to see if it makes a difference. Placard shows 36/39 F/R if loaded.s-l400.jpg
      I run 39-40 all around in the summer with no grip issues, lower to 35-36 in the winter. 32 is pretty low.

      Sent from my SM-N920V using Tapatalk
      2007 XC90 V8 Sport (R-Design), Passion Red, Large Iron Mark Grille, Satin Black Metallic Powder Coated Rims, 2013 Smoked Tail Lights, Lighted Upper Tail Lights, Chrome Executive Inlets, 32" Light Bar, Full Roof Rack w/ 36" Tri-Row Bar, 20" Light Bar, 4 7" Side Light Bars, 2 6" Back Up Light Bars, Full Sized Shovel, Full Sized Axe, Hi-Lift. S60R Brembo Brakes Front+Rear, 25mm Spacers, EBC Rotors+Pads.

    12. #10
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      Hey CDN, are you still happy with the LED bulbs? Still no Canbus issues?
      Excited to see the ride when you get the new springs


      Sent from my iPhone using Tapatalk

    13. #11
      Member oneofakind's Avatar
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      Quote Originally Posted by CDN XC90 View Post
      Planned:

      HEICO lowering springs
      HEICO Bilsteins
      IPD HD spring seats
      IPD strut brace brackets
      IPD subframe bushing inserts
      IPD sways
      Meyle HD endlinks
      Drawtite trailer hitch
      Custom Yonaka exhaust (prototype)
      Fast FC05 20" wheels with Conti DWS06 255/45/20
      Aftermarket subwoofer
      I think you should add the 2012+ lower and upper tail lights to this list. They really update the looks on these cars

      Sent from my SM-N920V using Tapatalk
      2007 XC90 V8 Sport (R-Design), Passion Red, Large Iron Mark Grille, Satin Black Metallic Powder Coated Rims, 2013 Smoked Tail Lights, Lighted Upper Tail Lights, Chrome Executive Inlets, 32" Light Bar, Full Roof Rack w/ 36" Tri-Row Bar, 20" Light Bar, 4 7" Side Light Bars, 2 6" Back Up Light Bars, Full Sized Shovel, Full Sized Axe, Hi-Lift. S60R Brembo Brakes Front+Rear, 25mm Spacers, EBC Rotors+Pads.

    14. #12
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by oneofakind View Post
      I run 39-40 all around in the summer with no grip issues, lower to 35-36 in the winter. 32 is pretty low.

      Sent from my SM-N920V using Tapatalk
      Good to know. I'll up the pressure some and see if it makes a difference.

      Quote Originally Posted by Killachiefdezil View Post
      Hey CDN, are you still happy with the LED bulbs? Still no Canbus issues?
      Excited to see the ride when you get the new springs


      Sent from my iPhone using Tapatalk
      Yes, very pleased. No errors. Need to save some pennies to do the fogs. The same bulb isn't available in H1 however and I'm thinking I'd like to go 3000k for the fogs but not sure yet. Will see when comes to ordering time.

      Quote Originally Posted by oneofakind View Post
      I think you should add the 2012+ lower and upper tail lights to this list. They really update the looks on these cars
      Trying to limit it to really functional mods for the most part. Function over form so to speak but the grille was purely cosmetic. It's got a tie-in to my last two vehicles so it gets a pass though

      Seriously though, I actually like my tails and the plastics almost look like new so I won't be thinking to change anytime soon. I will probably need polish the headlight lenses in the spring/summer however.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    15. #13
      Member RedGeminiPA's Avatar
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      I'm interested to see how you make out with putting LEDs in the fog lights, considering how they're made. There's a retainer that actually plugs into the bulb, holding it into the light housing, then a different connection for the actual wiring.
      2006 XC90 V8 w/ Climate, Touring, Convenience and RSE. Silver w/ Graphite
      2014 Lincoln MKT EcoBoost Elite, Tech, Pano, 20”, Rear Captains. Pearl/Black
      Past: 2008 XC90 V8 w/ Climate, BLIS, Dynaudio, Bi-Xenon. Ember black w/ Sandstone
      2004 XC90 2.5T AWD 7-Passenger w/ Climate, Premium and Versatility packages and Xenon headlights.

    16. #14
      Member oneofakind's Avatar
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      Quote Originally Posted by RedGeminiPA View Post
      I'm interested to see how you make out with putting LEDs in the fog lights, considering how they're made. There's a retainer that actually plugs into the bulb, holding it into the light housing, then a different connection for the actual wiring.
      I have amber ones in mine. They're not as bright as I'd like (cheap eBay specials), but it seemed like plenty of companies make that style.

      Sent from my SM-N920V using Tapatalk
      2007 XC90 V8 Sport (R-Design), Passion Red, Large Iron Mark Grille, Satin Black Metallic Powder Coated Rims, 2013 Smoked Tail Lights, Lighted Upper Tail Lights, Chrome Executive Inlets, 32" Light Bar, Full Roof Rack w/ 36" Tri-Row Bar, 20" Light Bar, 4 7" Side Light Bars, 2 6" Back Up Light Bars, Full Sized Shovel, Full Sized Axe, Hi-Lift. S60R Brembo Brakes Front+Rear, 25mm Spacers, EBC Rotors+Pads.

    17. #15
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by RedGeminiPA View Post
      I'm interested to see how you make out with putting LEDs in the fog lights, considering how they're made. There's a retainer that actually plugs into the bulb, holding it into the light housing, then a different connection for the actual wiring.
      Ok, haven't ever taken a look so will do that first to make sure there's clearance etc.

      The vendor recommended this one, not sure if you can tell by looking at the bulb if it would fit? https://www.aliexpress.com/store/pro...76ca8f77ltpfjM

      Built with "High LPW CSP LEDs". I'll need to research those a bit.
      Last edited by CDN XC90; 12-16-2017 at 04:48 PM.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    18. #16
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      Looking good, hope to see some more updates as you add things.


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      2006 XC90 V8 145k
      2004 BMW 330 XI
      2005 Ford F-150

    19. #17
      Member RedGeminiPA's Avatar
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      I'll be a little more specific. It's not that these won't "fit," but more about how they install. The fog light doesn't use any type of standard bulb method of install. They use a bulb holder with the H1 connection that screws into the socket, then a different type of plug connects to the holder.

      Here's a picture of the holder for reference.

      1021022.jpg
      2006 XC90 V8 w/ Climate, Touring, Convenience and RSE. Silver w/ Graphite
      2014 Lincoln MKT EcoBoost Elite, Tech, Pano, 20”, Rear Captains. Pearl/Black
      Past: 2008 XC90 V8 w/ Climate, BLIS, Dynaudio, Bi-Xenon. Ember black w/ Sandstone
      2004 XC90 2.5T AWD 7-Passenger w/ Climate, Premium and Versatility packages and Xenon headlights.

    20. #18
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by RedGeminiPA View Post
      I'll be a little more specific. It's not that these won't "fit," but more about how they install. The fog light doesn't use any type of standard bulb method of install. They use a bulb holder with the H1 connection that screws into the socket, then a different type of plug connects to the holder.

      Here's a picture of the holder for reference.

      1021022.jpg
      Thanks for that. I'll take a look to see myself but yes, that doesn't look all that straightforward for an aftermarket assembly...

    21. #19
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by CDN XC90 View Post
      Planned:
      Custom Yonaka exhaust (prototype)
      Dropped the vehicle off today for the prototype exhaust. I should have photos in a couple days. Exhaust will take a few months to go into production so it won't be available til spring at the earliest. More details to follow.

    22. #20
      Junior Member CDN XC90's Avatar
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      Last edited by CDN XC90; 12-19-2017 at 09:50 PM.

    23. #21
      Junior Member CDN XC90's Avatar
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      More progress:

      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    24. #22
      Junior Member CDN XC90's Avatar
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      Almost complete.

      Attachment 21969
      Attached Images Attached Images
      Last edited by CDN XC90; 12-22-2017 at 11:46 AM.

    25. #23
      Junior Member CDN XC90's Avatar
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      Prototype complete

      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    26. #24
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      so how does it sound? looks nice!
      2004 volvo xc90 2.5t awd

    27. #25
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by huzzsaba View Post
      so how does it sound? looks nice!
      No sound clips as far as I know but I'll ask. This was just a pre-production prototype. I'm not sure the tips were even sealed on the muffler as it looks like they modified a center outlet can.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    28. #26
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      Quote Originally Posted by CDN XC90 View Post
      I'm not sure the tips were even sealed on the muffler as it looks like they modified a center outlet can.
      Yeah, it looks like they tacked the tips on over the hole! Still, looks good! What engine are you fitting it to?
      John C
      ---------------------
      2011 XC90 3.2 171,000 miles and counting...

    29. #27
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by John C View Post
      Yeah, it looks like they tacked the tips on over the hole! Still, looks good! What engine are you fitting it to?
      It's a 2.5T but expected to fit all gas variants.
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    30. #28
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      Would be nice to get opinions from fellow xc90 owners on what it sounds like before putting it into production, no? Hopefully we can get a sound clip soon, and possible price.
      2004 volvo xc90 2.5t awd

    31. #29
      Junior Member CDN XC90's Avatar
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      So, it's full 3" and will be under US $500. There will be intro pricing I expect.

      I'm super stoked.

      No sound clips as this was initial prototype and muffler configuration not final. This was offset/center muffler but final will be offset/dual with a Y-pipe internal to the dual outlet slash tips.

      This prototype will go to Asia. Production sample will be sent back here for test fit and sound check. It's at this point that final pricing will be set and folks can sign up on wait list for initial run. It'll be a couple months from now.

      Last edited by CDN XC90; 12-23-2017 at 11:02 PM.

    32. #30
      Member RedGeminiPA's Avatar
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      So, it's expected to come in at around $500? If so, that's pretty good.
      2006 XC90 V8 w/ Climate, Touring, Convenience and RSE. Silver w/ Graphite
      2014 Lincoln MKT EcoBoost Elite, Tech, Pano, 20”, Rear Captains. Pearl/Black
      Past: 2008 XC90 V8 w/ Climate, BLIS, Dynaudio, Bi-Xenon. Ember black w/ Sandstone
      2004 XC90 2.5T AWD 7-Passenger w/ Climate, Premium and Versatility packages and Xenon headlights.

    33. #31
      Member oneofakind's Avatar
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      I'd buy one for around $500 as long as it sounds good!

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      2007 XC90 V8 Sport (R-Design), Passion Red, Large Iron Mark Grille, Satin Black Metallic Powder Coated Rims, 2013 Smoked Tail Lights, Lighted Upper Tail Lights, Chrome Executive Inlets, 32" Light Bar, Full Roof Rack w/ 36" Tri-Row Bar, 20" Light Bar, 4 7" Side Light Bars, 2 6" Back Up Light Bars, Full Sized Shovel, Full Sized Axe, Hi-Lift. S60R Brembo Brakes Front+Rear, 25mm Spacers, EBC Rotors+Pads.

    34. #32
      Junior Member CDN XC90's Avatar
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      Pretty sure it won't be more than $500 so definitely good value. I'll post updates as available but it will be a few months realistically. Start saving those pennies
      2006 XC90 2.5T AWD - Contrast Works Stage 2 tune with Eco Enhance mode, HEICO Bilsteins and springs, IPD Swaybars, strut brace conversion kit, and subframe bushing inserts. Fast FC05 20x8.5 with 255/45/20 Conti DWS06. Falken HS449 235/65/17 winters. JL 500/1 with Pioneer TS-SWX2502 subwoofer under cargo tray. LED low/hi beams, Tuxmats.

    35. #33
      Member RedGeminiPA's Avatar
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      I'd love to hear this on a V8... It's so tempting.
      2006 XC90 V8 w/ Climate, Touring, Convenience and RSE. Silver w/ Graphite
      2014 Lincoln MKT EcoBoost Elite, Tech, Pano, 20”, Rear Captains. Pearl/Black
      Past: 2008 XC90 V8 w/ Climate, BLIS, Dynaudio, Bi-Xenon. Ember black w/ Sandstone
      2004 XC90 2.5T AWD 7-Passenger w/ Climate, Premium and Versatility packages and Xenon headlights.

    36. #34
      Junior Member CDN XC90's Avatar
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      Quote Originally Posted by RedGeminiPA View Post
      I'd love to hear this on a V8... It's so tempting.
      Is your V8 a single outlet? I know there is a 'sport' exhaust that is dual but not sure all V8s came with them stock?

    37. #35
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      The exhaust on my 06' V8 is single outlet. Pretty gnarly too and an option to replace for around $500 would be awesome.

      I'm just wondering when something is going to rust through. I've already had to replace the catalytic converter...


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      2006 XC90 V8 145k
      2004 BMW 330 XI
      2005 Ford F-150

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