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BK's XC90 - “Polar Bear” / Dad Wagon

16K views 85 replies 21 participants last post by  BKXC90 
#1 · (Edited)
Starting a thread to help keep track of all the little things I've done on this beautiful beast. Because of my NWT plate, my kids have given our cars animal names; thus the Polar Bear was born.

This was my second Volvo; I had a 2005 V50 T5 wagon for a very short time before it blew its guts out. I also had a 2001 V70 T5M as a COVID project car. My fourth Volvo just joined the family - a 2008 C30 project car.

I've loved the XC90 since I first saw it as a kid. Been a dream car for me. Started reading about them, knew I had to have the V8 after having two underpowered cars in the past: an off-road Nissan Xterra and a base model Subaru Impreza (5 speed). Had been tossing around the idea of trading in my beloved Subaru for something a little bigger and a little sleeker. Found this XC90 V8 in Chicago with 65K on it and made the drive from Michigan to make the trade. Haven't regretted it for a second. Since then, here is a quick list of what I've done:

  • OEM hitch added (scrap yard find), OEM trailer harness (30756529), trailer module (30664974)
  • Rhino Rack aero bars
  • WeatherTech mats (all 4 + cargo mat)
  • Replaced fuse for navigation system that rendered it useless
  • Rear middle bench seat delete
  • Liftgate supports replaced
  • Tail lamps replaced (new LED style - 31335506 / 31335507)
  • Battery replaced
  • Splash guards added (OEM)
  • Subframe bushings
  • Exhaust repair - flex pipe
  • De-chromed a bit (C-pillar, rear strip, front lower grilles)
  • OEM Atlantis wheels (scrap yard find - refinished, repainted)
  • K&N air filter, fuel filter, OEM spark plugs at 71K miles (332328 / 30636704 / 30731383)
  • Map / GPS system update to 2015
  • Stabilizer bar braces replaced
  • O2 sensor replaced (Bosch 15179)
  • Tires - Yokohama Geolandar AT G015 235/60R18 (winter rated)
  • Meyle HD front and rear end links
  • Fuel cap replaced, Swedish front plate
  • Upper and PS lower engine mounts replaced (30723146 / 30723702)
  • Cabin air filter, dual rear fog lights (8693010), strut stabilizer bar repainted
  • Front and rear brakes / rotors (Zimmerman 336mm)
  • Roof rail delete (8667805 x2, 8667806 x2, 8667807 x2, 31250206 x2, 30655393 x2, 31250205 x2)
  • Rear door taxi washers (9487627)
  • DRL disable through VIDA
  • New V8 emblem for engine (30731838)
  • Aluminum "sport" pedals
  • Swede Solutions P2 litecam
  • Tires - Michelin CrossClimate2 235/60R18 XL 107V (winter rated)
  • Euro style rearview mirrors or Volvo part 31297395
  • Transmission fluid flush at 89,000 miles (Mobil 3309)
  • S60 donor seat swap and steering wheel
  • Front suspension refresh - Bilstein B4 Touring struts, Meyle control arms, strut mounts

    To do:
  • 3rd row cargo barrier (8641489)
  • Decal site
  • Nivomat conversion kit

Brought home June 2018 / V1:


December 2020 / V2:
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August 2021 / V3:
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#6 · (Edited)
Sorry, I do not. That repair was done by our local Euro shop. I can ask and see if they know.

Friday was a productive day - OE spark plugs, Wix fuel filter, K&N air filter, and the OE trailer tow harness. I need to read more about the harness in regards to the trailer module itself. The instructions dirdcted me to take off the rear panel above the wheel well to access the trailer module, but I didn't have enough time to find out if my car came with it or not. Guessing no, but I do not want to purchase it if it's either already there or if it's not needed. I doubt I will ever pull a trailer with brakes using the XC. I plugged in the harness to the fuse panel and the fuses were already correctly populated, but I am still getting just an aux signal from the 7 pin. Need to grab the schematic and keep digging. I was happy to find that the spark plugs were just as challenging as I expected - not too easy and enough to keep it interesting.
 
#9 ·
Looking into tightening up the suspension and steering; tie rods, stabilizer bars, etc. Other than that, we had winter for a brief, cold week. [/QUOTE]

If you want an excellent suspension and steering set-up, check out Chitown-V's upgrade guide.
[URL]https://forums.swedespeed.com/showthread.php?590829-ChitownV-my-front-end-rebuild-upgrade-using-OEM-amp-aftermarket-parts[/URL]
 
#14 ·
Finally got around to the 5K oil change, and had the TPMS sensors programmed. Replaced the Blizzaks with a high-performance winter rated SUV tire - Michelin CrossClimate SUV in the same size (235/60R18). Finally, added an extended length Thule basket up top. Had the standard version (Canyon XT) but it just didn't fill out the roof enough. The extended fits a little better and definitely hauls more toilet paper & Volvo parts.
 
#15 ·
I never did take to the XC90 like my wife did and I maintain it only to what wears out. I am actually pleasantly surprised at how well it is holding up but perhaps understandable since this car rarely sees 100 km/H (60MPH).

That's quite a rack you put on your car but gosh those Blizzaks still look good to me. I am leaving the Gislaved winter tires on for the summer and will replace with same in the fall. They are almost to the wear bars but have been on for 12 seasons now.
 
#18 ·
It's so hard to stay away from the exhaust sections on FCP and iPD. Then I see the prices and it's super easy!
However, over the winter I was on the receiving end of a hit-and-run. The rear part of my lower fascia (silver part near the hitch) is cracked and needs to be replaced. Which means I could order the one for a dual exhaust instead...then it would make a nice, throaty, dual exhaust much easier to justify, right?! :D
 
#22 · (Edited)
Nice thread and writeup! My 60K mile 08 XC90 V8 is on its way from Texas right now and should be here later this week. Always good to connect with another SE Michigan Volvo enthusiast, there aren't many of us.

Still have the Blizzaks? I may be interested in grabbing them if you do.

Not sure where you're having the work done, but my mechanic was the Yamaha V8 specialist at one of the local Volvo shop, so he'll be taking good care of this one too. Happy to share his contact info if you're looking, he's generally way cheaper than all of the other shops in the area.
 
#23 ·
Thanks and great meeting you! I work close to Steve's Euro, which is where I have been taking both Volvos if they need something more than what I'm comfortable wrenching on. I'm going to need the timing belt service done soon on the V8 (based on age rather than mileage - only at 77K). It would be great to get the info of your mechanic too.

Regarding the Blizzaks - they are gone. However, I need a more chunky tire than the Michelins I put on. They are great and super grippy (and winter rated) but the roads I drive demand some beef. I'm going to replace them soon, so they'll be available if you're interested. I really like these Michelins, but you know as well as I do that there are no smooth roads around here :D I drive a ton of dirt and gravel so I'm leaning towards Yokohama Geolandars. I've had those on a few cars now and they're perfect - chunky but not too aggressive, capable, and winter rated.
 
#26 · (Edited)
Thanks - I was reading another thread and didn't realize they were talking about the serpentine belt :D

Finished swapping sway bar end links (front and rear). Ended up with the Meyle HD links and they are beefy. I swear I feel less body roll, and it's wonderful. The old links may have been original, but either way they were getting pretty worn out.
 
#27 · (Edited)
Starting some maintenance items - just rolled over 80K miles on this car. Had a couple of small road trips that really hammered on some miles pretty quickly. Shocks and struts are on the short list since I'm pretty sure it's still on factory original suspension other than the Meyle HD links I put on.

New tires mounted - Yokohama Geolandar G015 (winter rated). I also started to undertake a "chrome delete" project because I hate it. I didn't want to paint it or order new parts, so I put on some black Plasti-Dip for now. Not as permanent as paint and there's not nearly as much chrome. Not sure what to do with the grille just yet, but the lower grilles (3 pieces) are dipped with 10 coats each. The C-pillar panels are also black. Might do some detail work on the Executive emblems. Lastly, the rear chome strip under the V O L V O badge is black. Trying not to "black out" the whole car.

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#28 · (Edited)
Picked up these Xenon bulbs with ballasts, going to try to get them to work. Need to figure out if / how they'll work with my headlamps.

Also need to look into replacing this lower valance. Got rear-ended last winter (hit and run). Easy to replace, but thinking about future exhaust options.... if I need a new muffler / exhaust, I'd try to look into the dual exhaust setup, even though it's insanely expensive. Should I go for the dual cutout valance now? Will it look silly with a single exhaust? Absolutely.
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#29 ·
Hey BK, regarding those xenons - from what I understand they need to be installed into projectors so as to not blind oncoming traffic. I've been considering installing a pair of retrofit projectors into the stock XC90 headlight housing from here:
https://www.retrofitlab.com/
 
#30 ·
HIDs light up the road so much better and they look good too. I like the direction here. I installed retrofit HIDs on three sets of halogen housings. The issues for me for going original were, the original housings cost too much and used ones will already be hazy or the reflector started to wear & yellow, without the right wiring the car will show a lamp-out message, and I wanted the newer better looking projector HIDs but those are with active bending. The price of purchasing one used Volvo HID housing almost cost the same as me buying new halogen housings and the HID projector retrofit kit. In the future if I need a new housing, the aftermarket halogen housings are much more affordable and individual HID parts are cheaper too. The bulb is a standard D2S bulb size that is OEM on many different vehicles so the selection of bulbs is nice. I've been running mine for almost 3 years now.

I purchased my Morimoto kit on Retrofitsource and they have a sale ending today.

Here are some images for your reference so you can see how retrofits look on my '08 (top) and an '06 (below, wanted to show on a black color XC90 like yours):





 
#32 · (Edited)
1. Front end refresh - pale yellow tint over the fog lights, Swedish plate.
2. Tires rotated before winter.
3. Engine mounts - all 3 ordered but only two were needed. Replaced the upper and the lower PS. The torque mount / rod was in great condition, almost as good as the new one that was ordered. Could have been replaced before I owned the car. Had the strut bar off and found some surface rust, so it got cleaned up and painted with the same wheel paint I used. Subtle detail and I like it. Cleaned up the spare tire and painted it the same. Wondering if there's a way to clean up that crap on the engine. What a difference the lighting makes! Strut bar mounts, upper engine mount, lower PS mount all replaced now.
4. Working on brakes - rotors weren't the right size (need 336mm) but cleaned up the hubs, painted the calipers black, and ordered the right size rotors.
5. Exhaust is next on the to-do list. The center muffler is rusting, peeling, and getting worse. Not going to replace it - just going to have a shop remove it and straight pipe that section. Should sound a little better too.
6. Still working on suspension. Quick shop inspection said there's nothing obvious that is leading to my ride quality suffering so I haven't ordered any struts or anything yet. Need to take it to an indy shop for a real inspection before I start throwing parts at it.
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#33 · (Edited)
Continuing some pre-winter maintenance. Mahle cabin filter - T25 Torx, ten minutes, $25. Wasn't as dirty as I thought it would be, but still too easy and cheap to skip over it (left is new, right is old). New lower PS engine mount made all the difference. Engine vibration on acceleration is all but gone. Old one was in good shape but rubber was cracked.

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#35 ·
Continuing some pre-winter maintenance. Mahle cabin filter - T25 Torx, ten minutes, $25. Wasn't as dirty as I thought it would be, but still too easy and cheap to skip over it (left is new, right is old). New lower PS engine mount made all the difference. Engine vibration on acceleration is all but gone. Old one was in good shape but rubber was cracked.
Been enjoying reading through this thread! For the lower engine mount, did you do that yourself? I've done the upper one myself and still have (reduced) vibration on acceleration. If a shop did it, do you know how many hours labour it took? Thanks!
 
#37 ·
Parts are on order for the roof rail delete and the rear door taxi mod! On back order, but still excited. Should help over the winter - the XC just barely clears my garage door. Working on it in the garage will be so much better with that extra height clearance.

  • Roof rail delete (8667805 x2, 8667806 x2, 8667807 x2, 31250206 x2, 30655393 x2, 31250205 x2)
  • Rear door taxi washers (9487627)
 
#38 ·
Roof rail delete and rear door taxi mod are complete. The roof rail delete came about due to boredom. I was rolling with a Thule basket, crossbars, and rails since I had it. This was something that ended up sending me down a rabbit hole. Big thanks to Mark (xyphur) for his help on getting this done. I'm a huge fan of how it turned out.

The rear taxi doors didn't change the way I wanted, but still cool. They do indeed open the door wider. I was hoping it would increase the distance between the door panel and the seat, enabling more space for the kids to get in and out. Nevertheless, a cool little modification.

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#40 ·
Will report back after some real driving (and car wash). You can see from the height of my garage door that I was having the same issue! Here is the thread I made with the part numbers:

 
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