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2003 Volvo XC90 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volvo REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Volvo -> Component Replacement & Adjustment -> Water Pump, Replace
Vehicle: 2003 Volvo XC90 2.5 L5 GAS
- Open drain petcock on engine block and drain coolant into suitable container.
- Remove coolant expansion tank cap and drain coolant into suitable container.
- Remove timi...
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BRAKE SERVICE PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Anti-lock Brakes -> Troubleshooting -> Component Fault Tracing
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
Component Fault Tracing
All procedures must be completed to avoid damaging the control unit.
Refer to wiring diagram and component locations in Figs. and , during fault tracing procedures.
- Inspect fuse in transient surge protector
- Inspect all connectors, wires and ground connections for ABS System.
- Switch ignition off.
- Disconnect connector from control unit by depressing lock spring and swinging connector out.
- Remove cover from hydraulic modulator.
- Remove cover from control unit connector.
- Remove white protective moldings from sides of connector.
- Inspect ground connections in connector.
- A...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Volvo -> Fuel Filter Scheduled Maintenance -> 2003 XC90 w/2.5L Engine -> Normal Service -> Severe Service
Vehicle: 2003 Volvo XC90 2.5 L5 GAS
Normal Service
Replace at 1...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
CV AXLE SHAFT, Replace -> Left Side -> Rear -> Right Side
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
Left Side
- Raise and support vehicle on lift.
- On models with AWD, remove drain plug and drain transmission fluid.
- On all models, remove front wheel lug nuts.
- Remove bolt for wheel hub driveshaft.
- Counterhold using a suitable tool in brake disc vents.
- Tap end of drive shaft approximately 20-25mm into wheel hub.
- Remove nut for ball joint and control arm. If ball joint pinion moves, counterhold end of lug using suitable tool.
- Disconnect ball joint pinion from control arm using suitable tool.
- Install cap nut using suitable tool on ball joint pinion.
- Tighten nut against control arm, the...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Alternator, Replace
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
- Disconnect battery ground cable.
- Detach pipe from control module box.
- Rotate or lift belt tensioner arm counterclockwise, using a suitable tool to relieve tension from drive belt.
- Remove drive belt.
- Loosen clamps and remove power steering pump hoses. Drain fluid in a clean suitable container. Avoid skin contact with power steering fluid.
- Remove cold air inlet hose to control module.
- Loosen bolt on power steering line lock bracket.
- Loosen pipe nipple on pump.
- Remove bolts from power steering pump pulley holes and lift pump up to remove.
- Loosen hose clamps, disconnect coolant hose from...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
The cabin air filter should be replaced every 15,000 miles. The filter should be replaced more often if air flow is less than normal.
- Remove the sound proofing panel from under the passenger side of the instrument panel.
- Remove the cabin air filter cover retaining screws, then the cover, Fig. .
- Press down on the cabin air filte...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Volvo -> Anti-Lock Brake System (ABS)/Dynamic Stability & Traction Control (DSTC)/Stability Traction Control (STC) Warning Lamp ->
Vehicle: 2003 Volvo XC90 2.5 L5 GAS
The warning lamp is used to warn of an system fault. The lamp input monitors the condition of the system. The lamp will be lit during engine start-up, but should go out when the self-diagnostic sy...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition clamp on heat exchanger feed pipe and remove hose.
- Reposition clamp on cylinder head nipple and remove hose.
- Remove hose from vehicle.
- Reverse procedur...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
- Remove air duct cover, surround and control module box.
- Seal expansion tank to thermostat housing hose using suitable hose clamping pliers, then disconnect hose from expansion tank and position tank aside.
- Lift servo reservoir from mounting bracket and position on top of engine. Ensure oil does not leak from filler cap.
- Rotate accessory drive belt tensioner clockwise, using ...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Volvo XC90 AUTOMOBILES
Component location diagrams for most 2003 Volvo XC90 cars and light trucks sold in the U.S. from 1990+.
Body Component Locations Diagram for 2003 Volvo XC90 2.5 L5 GAS Components on diagram: |
Front End Component Locations Diagram for 2003 Volvo XC90 2.9 L6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2003 Volvo XC90 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Volvo XC90 cars and light trucks sold in the U.S.
2003 Volvo XC90 2.9 L6 GAS Wiring Diagram Components on diagram: |
2003 Volvo XC90 2.9 L6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Volvo XC90 AUTOMOBILES
OEM TSB listings for most 2003 Volvo XC90 cars and light trucks sold in the U.S. from 1985+.
Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2003 Volvo XC90 2.5 L5 GAS Auto Systems: |
Document: TRANSMISSION CONTROL MODULE (TCM), SOFTWARE (SW) - REVISED Vehicle: 2003 Volvo XC90 2.5 L5 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Volvo XC90 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 Volvo XC90 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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