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2003 Volvo S80 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 Volvo S80 car and truck
repair procedures including Volvo engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Volvo S80 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Volvo -> Automatic Temperature Control System Diagnosis & Testing -> Precautions -> Air Bag System Disarming & Arming -> Anti-Theft Audio Systems -> Battery Ground Cable -> Product Compatibility
Vehicle: 2003 Volvo S80 2.9 L6 GAS
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming procedures.
Product Compatibility
Before replenishing refrigerant or refrigerant oil, ensure product is compatible with the system being serviced. Refer to for specifications.
Anti-Theft Audio Systems
Obtain radio anti-theft code from vehicle owner and record station presets, then turn radio off before disconnecting or connecting battery ground cable to prevent radio damage.
The coded anti-theft system will disable the radio when battery power is inte...
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BRAKE SERVICE PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Hydraulic Brake Systems -> Component Service -> Assemble -> Cleaning & Inspection -> Disassemble -> Master Cylinder Overhaul
Vehicle: 2003 Volvo S80 2.9 L6 GAS
Master Cylinder Overhaul
Disassemble
- Remove reservoir from master cylinder.
- Drain fluid from reservoir, then remove seals.
- Remove circlip and withdraw pistons and return spring.
Cleaning & Inspection
- Polish inner surface of the master cylinder with a honing tool (cylinder grinding tool).
- Clean all pistons components and cylinder with methylated spirits.
- Blow compressed air into the equalizer and overflow holes.
- Inspect master cylinder bore for scoring, ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Volvo -> Component Locations -> 2003-06 Volvo XC90, 2001-06 S60, 2000-04 S40 & V40, 1999-06 S80, 1998-06 C70, S70, V70 & 1992-97 850
Vehicle: 2003 Volvo S80 2.9 L6 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Driveshaft, Replace
Vehicle: 2003 Volvo S80 2.9 L6 GAS
- Raise and support vehicle on lift.
- Remove front member from body, exhaust pipe and Three-Way Catalytic Converter.
- Remove brake pipe from mountings in member. If the same driveshaft is to be reinstalled. Mark the driveshaft CV joint in relation to the bevel gear flange.
- Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.
- Remove rear exhaust system assembly.
- Remove bolts from joint using suitable tool to hold driveline while removing bolts.
- Leave one bolt in place by a few threads for safety.
- On models with vibration dampner, hold driveline...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Alternator, Replace
Vehicle: 2003 Volvo S80 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 S80 AUTOMOBILES
Cabin Air Filter Service -> Volvo -> 1999-2006 S80, 2001-09 S60, 2001-07 V70, XC70 & 2003-09 XC90
Vehicle: 2003 Volvo S80 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 S80 AUTOMOBILES
Volvo -> Air Bag Warning Lamp ->
Vehicle: 2003 Volvo S80 2.9 L6 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Radiator, Replace
Vehicle: 2003 Volvo S80 2.9 L6 GAS
- Discharge A/C system.
- Remove coolant expansion tank cap, then raise and support vehicle.
- Remove skid plate from under engine, then open drain cock, drain coolant into suitable container.
- Remove retaining bolt form cable guide, then place cable guide on sub-frame.
- Disconnect air duct from sub-frame retaining clips.
- Disconnect lower oil cooler hose at cooler unit, then plug oil cooler and hose openings.
- Lower vehicle, then remove hose from expansion tank.
- On models equipped with turbocharger, remove righthand and lefthand Charge Air Cooler (CAC) hoses from CAC.
- On all models, disconnect...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Volvo S80 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Volvo S80 2.9 L6 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Volvo S80 AUTOMOBILES
Component location diagrams for most 2003 Volvo S80 cars and light trucks sold in the U.S. from 1990+.
 Alternator Diagram for 2003 Volvo S80 2.9 L6 GASComponents on diagram: |
 Lock And Alarm Components Diagram for 2003 Volvo S80 2.9 L6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2003 Volvo S80 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Volvo S80 cars and light trucks sold in the U.S.
 2003 Volvo S80 2.9 L6 GAS Wiring DiagramComponents on diagram: |
 2003 Volvo S80 2.9 L6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Volvo S80 AUTOMOBILES
OEM TSB listings for most 2003 Volvo S80 cars and light trucks sold in the U.S. from 1985+.
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Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2003 Volvo S80 2.9 L6 GAS Auto Systems: |
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Document: TRANSMISSION CONTROL MODULE (TCM), SOFTWARE (SW) - REVISED Vehicle: 2003 Volvo S80 2.9 L6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Volvo S80 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Volvo S80 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 S80 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 S80 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 S80 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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