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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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 Volvo XC90 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 XC90 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Volvo -> Component Replacement & Adjustment -> Expansion Valve, Replace -> C70, S70 & V70
Vehicle: 2003 Volvo XC90 2.9 L6 GAS
C70, S70 & V70
- Recover refrigerant as outlined under .
- Disconnect expansion tube from evaporator.
- Remove expansion tube from pressure line using suitable needle nose plier...
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BRAKE SERVICE PROCEDURES FOR 2003 Volvo XC90 AUTOMOBILES
Hydraulic Brake Systems -> Component Service -> Assemble -> Cleaning & Inspection -> Disassemble -> Master Cylinder Overhaul
Vehicle: 2003 Volvo XC90 2.5 L5 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 XC90 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 XC90 2.9 L6 GAS
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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 2.5 L5 GAS
- Raise and support vehicle.
- Remove front member from body, exhaust pipe and three-way catalytic converter (TWC).
- Remove brake pipe from mountings in member.
- Remove front propeller shaft. If same propeller shaft is to be reinstalled, mark propeller shaft CV joint in relation to bevel gear flange.
- Remove screws from propeller shaft. Use a suitable counterhold tool.
- Remove rear section of exhaust system.
- Support front section of exhaust pipe so as not to put strain on exhaust manifold.
- Remove rear exhaust system assembly.
- Remove rear propeller shaft. If same propeller shaft is to be reu...
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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 2.5 L5 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 -> Air Bag Warning Lamp ->
Vehicle: 2003 Volvo XC90 2.5 L5 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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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 GASComponents on diagram: |
 Instrument Panel Component Locations Diagram for 2003 Volvo XC90 2.5 L5 GASComponents 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 2.5 L5 GAS Wiring DiagramComponents on diagram: |
 2003 Volvo XC90 2.9 L6 GAS Wiring DiagramComponents 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+.
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Document: DIFFERENTIAL ELECTRONIC MODULE (DEM), SOFTWARE (SW) - REVISED Vehicle: 2003 Volvo XC90 2.5 L5 GAS Auto Systems: |
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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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