2003-2010 Volvo XC90 Service Repair Manual

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🏷️ Basic Information Identification Make: Volvo Model: XC90 Generation: First Generation Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Market: USA/Canada 👋 Introduction Market Position Positioning: Premium SUV...

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Type: Car

Vendor:

Sku: 556239

Tags: 2003 2004 2005 2006 2007 2008 2009 2010 Car Cars Featured Volvo XC90

Product variants

Description

🏷️ Basic Information

Identification

Make:

Volvo

Model:

Generation:

First Generation

Years Covered:

2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Market:

USA/Canada

👋 Introduction

Market Position

Positioning:

Premium SUV offering a blend of safety, comfort, and Scandinavian design. Positioned as a family-oriented luxury vehicle.

Competitive Analysis

Key Competitors:

BMW X5, Mercedes-Benz M-Class, Audi Q7, Lexus RX, Acura MDX.

Key Features

Safety Focus:

Renowned Volvo safety systems, including advanced structural design and safety features.

Utility:

Spacious interior, optional third-row seating, all-wheel-drive capability.

Manual Value Proposition

Value:

Provides extensive technical information for DIY mechanics and professional technicians, enabling cost-effective maintenance and repairs.

📋 Manual Details

Coverage Areas

Engine Overhaul Rebuilding:

Brakes:

Sunroof:

Timing Belt Replacement:

Trouble Codes:

Wiring Diagrams:

Troubleshooting Diagnostics:

Engine Performance:

Front End Procedures:

Suspension:

Transmission Information:

Air Conditioning Service:

Capacities:

Computer Diagnostic Codes:

Firing Orders:

Detailed Specifications:

Factory Maintenance Schedules:

Serpentine Belt Routings:

Timing Belt Service Procedures:

Driving Concerns:

Complete Torque Specifications:

U Joint Cv Joint Service:

Repair Procedures:

Hundreds Of Illustrations:

Page Count

Estimated Page Count:

Thousands (as stated in product description)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine overhaul and rebuilding, timing belt service, engine performance, firing orders, serpentine belt routings, transmission information, U-joint and CV-joint service.

Chassis:

Brakes, suspension, front-end procedures and specifications.

Electrical And Electronics:

Wiring diagrams, computer diagnostic codes, troubleshooting and diagnostics.

Comfort And Convenience:

Sunroof service, air conditioning service.

Body And Frame:

Implied through general repair procedures and illustrations.

Procedures Included

Routine Maintenance:

Factory maintenance schedules and charts, fluid capacities.

Diagnostic And Troubleshooting:

Trouble codes, computer diagnostic codes, troubleshooting and diagnostics.

Repair And Rebuilding:

Engine overhaul and rebuilding, timing belt replacement, brake repair, suspension repair, transmission service, sunroof repair, U-joint and CV-joint service.

Technical Adjustments:

Front-end procedures and specifications, complete torque specifications.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to full engine rebuilding and detailed diagnostics. Includes factory-level detail.

Visual Aids

Illustrations:

Hundreds of illustrations for visual guidance.

📊 Manual Specifications

File Format

Format:

Accessibility:

Works on all computers (PC & Mac), Linux compatible.

Print Quality

Zoom Capability:

Allows zooming for detailed viewing of parts.

Printable Pages:

Ability to print out any required pages without manual damage.

Binding Type

Binding:

Digital (PDF download) - No physical binding.

Paper Type

Paper Type:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Options 2003-2004:

2.5L Turbocharged Inline-5 (B5254T2, ~208 hp), 4.4L Naturally Aspirated V8 (B8444S, ~311 hp)

Engine Options 2005-2006:

2.5L Turbocharged Inline-5 (B5254T2, ~208 hp), 4.4L Naturally Aspirated V8 (B8444S, ~311 hp)

Engine Options 2007-2010:

3.2L Naturally Aspirated Inline-6 (B6324S, ~235 hp), 4.4L Naturally Aspirated V8 (B8444S, ~311 hp)

Performance

Horsepower Range:

Approximately 208 hp to 311 hp depending on engine and model year.

Torque Range:

Approximately 236 lb-ft to 325 lb-ft depending on engine and model year.

Fuel System

Type:

Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI).

Timing System

Inline 5:

Timing belt

Inline 6 And V8:

Timing chain

🔧 Transmission

Standard

Inline 5 2003-2006:

5-speed Geartronic Automatic (AW55-50SN/AW55-51SN)

Inline 6 2007-2010:

6-speed Geartronic Automatic (TF-80SC)

Optional

V8 Models:

6-speed Geartronic Automatic (Aisin TF-80SC or similar for V8)

Features

Geartronic Tiptronic:

Manual shifting mode for driver engagement.

All Wheel Drive:

Standard on most models, often Haldex system.

📐 Dimensions

Exterior

Length:

Approx. 189.7 inches

Width:

Approx. 74.7 inches

Height:

Approx. 67.7 inches

Wheelbase:

Approx. 112.6 inches

Weights

Curb Weight Range:

Approx. 4,400 - 4,800 lbs, depending on engine and configuration.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for driver and front passenger, 2003-2004 models, and subsequent years as applicable)

IIHS Top Safety Pick:

Many model years received 'Good' ratings in IIHS front and side impact tests, often earning Top Safety Pick designations.

Active Features

Standard Anti-lock Braking System.

Standard Electronic Stability Control (ESC).

All-Wheel Drive (AWD) available/standard for enhanced traction.

Passive Features

Airbags:

Front airbags, side airbags, optional Inflatable Curtain (IC) side airbags for all rows.

Rollover Protection:

Roll Stability Control (RSC) introduced later in the generation.

💡 Technology Features

Infotainment

Audio System:

Various Dynaudio premium sound systems available, often with CD player and auxiliary input. Later models offered optional Sirius satellite radio and Bluetooth connectivity.

Navigation:

Optional factory navigation system, typically integrated into the dashboard display.

Driver Assistance

Cruise Control:

Standard cruise control. Adaptive Cruise Control (ACC) became available on later models.

Parking Assist:

Rear parking sensors became available on later models.

Connectivity

Bluetooth:

Available on later models for hands-free calling and audio streaming.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 7,500 to 10,000 miles or 12 months, depending on driving conditions and oil type used. Consult manual for specifics.

Timing Belt:

For 5-cylinder engines (B5254T2), recommended replacement around 70,000-100,000 miles or 7-10 years. Consult specific year/engine in manual.

Transmission Fluid:

Intervals vary; often recommended around 50,000-100,000 miles or as per dealer recommendation. Check manual for specific fluid type and procedure.

Fluid Specifications

Engine Oil:

Refer to specific viscosity grade (e.g., 0W-30 or 5W-30) and API/ACEA specifications. Volvo's own specifications often apply (e.g., VCC 95200356 for some models).

Coolant:

Volvo Blue or Green coolant (ethylene glycol based) is typically specified. Check manual for exact type and capacity.

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for exact specification).

Known Issues

Ignition Coils:

Common misfire issues often related to failing ignition coils, particularly on early 5-cylinder models.

Pcv System:

Clogged Positive Crankcase Ventilation (PCV) system can lead to oil leaks, rough idle, and seal failures.

Transmission Issues:

Some early transmissions (AW55-50SN/51SN) could experience shifting problems or failure if not maintained properly.

Strut Mounts:

Worn strut mounts can cause noise and affect handling.

📚 Vehicle History

Brand Heritage

Heritage:

Volvo is renowned for its pioneering safety innovations and robust vehicle engineering, particularly in the area of crash protection.

Model Evolution

Introduction:

The first-generation XC90 was introduced in 2002 for the 2003 model year, designed as Volvo's first SUV.

Major Updates:

Facelifted for the 2007 model year, featuring updated styling (front and rear fascias), a new inline-6 engine option (3.2L), and interior enhancements.

Production

Platform:

Based on Volvo's P2 platform, shared with other Volvo models like the S80, V70, and XC70.

Manufacturing Location:

Torslanda Plant, Sweden; also assembled in Ghent, Belgium.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Consistently recognized for safety by organizations like IIHS and NHTSA, earning numerous awards throughout its production run.

Ratings

Car And Driver Best SUVs:

Frequently cited by automotive publications for its blend of safety, utility, and comfort.