2003 Volvo XC90 Service and Repair Manual

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Factory-Grade Data

2003 Volvo XC90 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • T6 Sport Utility 4-Door
  • Base Sport Utility 4-Door

Engines covered

  • 2.9L 2917CC l6 GAS DOHC Turbocharged
  • 2.5L 2521CC l5 GAS DOHC Turbocharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2003 Volvo XC90 Recalls & Complaints

NHTSA #09V48300018/12/2009Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIF

Consequence

IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE

Remedy

DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP

NHTSA #03V39100010/10/2003Component: SEAT BELTS:REAR/OTHER

ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.

Consequence

IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF IN

Remedy

DEALERS WILL INSPECT AND REPAIR THE SECOND AND/OR THIRD ROW SEAT BELT ATTACHMENTS. OWNER NOTIFICATIO

NHTSA #10V56600008/11/2010Component: EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy

VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE

TSB #11032678

This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.

TSB #11032671

This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval. Curren

TSB #11027173

This is a Technical Journal. Vehicle type and platform identification.

TSB #11020437

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C

TSB #11016002

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i

TSB #11015994

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing i

TSB #11014113

This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory

TSB #11014112

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. C

Showing the 8 most recent of 239 technical service bulletins on file with NHTSA.

20040706Component: STEERING:HYDRAULIC POWER ASSIST SYSTEMCrash reportedFire reported1 injured

WHILE BACKING PUT OF A PARKING LOT POWER STEERING FAILED, VEHICLE SMOKED THEN CAUGHT ON FIRE. DRIVER SUFFERED FROM SMOKE INHALATION. *AK PRIOR TO THE VEHICLE CATCHING ON FIRE THE CONSUMER WAS INVOLV

20040706Component: AIR BAGSCrash reportedFire reported1 injured

WHILE BACKING PUT OF A PARKING LOT POWER STEERING FAILED, VEHICLE SMOKED THEN CAUGHT ON FIRE. DRIVER SUFFERED FROM SMOKE INHALATION. *AK PRIOR TO THE VEHICLE CATCHING ON FIRE THE CONSUMER WAS INVOLV

20040123Component: SEATS:FRONT ASSEMBLY:RECLINERCrash reported3 injured

I WAS INVOLVED IN A REAR-END COLLISION WITH MY 2 CHILDREN IN A VOLVO XC90. MY SEAT BACK FAILED DURING THE ACCIDENT AND I AM NOT REFERRING TO THE WHIPS SYSTEM. I SUSTAINED MULTIPLE INJURIES INCLUDING A

20060815Component: ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOODFire reported

WE HAD TRAVELED ABOUT 200 MILES IN THE MORNING WITH NO PROBLEMS WITH THE CAR. WE STARTED OUT AFTER LUNCH, WENT ABOUT 200 YARDS, AND SMELLED A FAINT BURNING SMELL WE THOUGHT WAS OUTSIDE THE CAR. AFTE

20131129Component: ELECTRICAL SYSTEM1 injured

I WAS NOT AWARE OF THE DESIGN DEFECT IN SUN ROOF & THE WATER DAMAGES THAT RESULT IN ELECTRICAL ISSUES. I HAD ALWAYS PARKED MY VEHICLE IN COVERED PARKING UNTIL MOVING THIS YEAR IN JANUARY. I HAD TAKEN

Showing the 5 most serious of 149 complaints filed with NHTSA.

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