light VOLVO XC90 2003 Repair Manual

2003 VOLVO XC90
beneficial.
l Before applying polish or wax the vehicle must be washed and dried. Tar \
spots can be removed with
kerosene or tar remover. Difficult spots may require a fine rubbing comp\
ound.
l After polishing use liquid or paste wax.
l Several commercially available products contain both polish and wax.
l Waxing alone does not substitute for polishing a dull surface.
l A wide range of polymer-based waxes can be purchased today. These waxes \
are easy to use and
produce a long-lasting, high-gloss finish that protects the bodywork aga\
inst oxidation, road dirt and
fading.
l Do not polish or wax your vehicle in direct sunlight (the surface of th\
e vehicle should not be warmer
than 113° F (45° C).
Cleaning the upholstery
l The fabric can be cleaned with soapy water or a detergent. For more diff\
icult spots caused by oil, ice
cream, shoe polish, grease, etc., use a clothing/fabric stain remover.
l The plastic in the upholstery can be cleaned with a soft cloth and mild \
soap solution.
l Leather upholstery/suede-like upholstery (alcanteraTM) can be cleaned with a soft cloth and mild soap
solution. For more difficult spots, Volvo offers a leather care kit.
l Under no circumstances should gasoline, naphtha or similar cleaning agen\
ts be used on the plastic or
the leather since these can cause damage.
Cleaning the seat belts
Clean only with lukewarm water and a mild soap solution.
Cleaning floor mats
The floor mats should be vacuumed or brushed clean regularly, especially\
during winter when they
should be taken out for drying. Spots on textile mats can be removed wit\
h a mild detergent.
Bear in mind
l Take extra care when removing stains such as ink or lipstick since the c\
oloring can spread.
l Use solvents sparingly. Too much solvent can damage the seat padding.
l Start from the outside of the stain and work toward the center.
pg. 112 Vehicle care
Paint touch up
Paint damage requires immediate attention to avoid rusting. Make it a ha\
bit to check the finish regularly
- when washing the vehicle for instance. Touch-up if necessary.
Paint repairs require special equipment and skill. Contact your Volvo re\
tailer for any extensive damage.
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2003 VOLVO XC90
However, for optimum road holding on icy or snow-covered roads, we recom\
mend suitable winter tires
on all four wheels. When replacing tires, be sure that the new tires are\
the same size designation, type
(radial) and preferably from the same manufacturer, on all four wheels\
. Otherwise there is a risk of
altering the vehicle's roadholding and handling characteristics.
NOTE: When storing wheel/tire assemblies (e.g. winter tires and wheels), eit\
her stand the assemblies
upright, or suspend them off the ground. Laying wheel/tire assemblies on\
their sides for prolonged
periods can cause wheel and/or tire damage.
New tires
Remember that tires are perishable goods. As of 2000, manufacturing year\
and week will be indicated
with 4 digits (e.g. 0015 means that the tire is manufactured year 2000,\
week 15).
Improving tire economy:
l Maintain correct tire pressure. See the tire pressure label on the insid\
e of the fuel filler door.
l Drive smoothly: avoid fast starts, hard braking and tire screeching.
l Tire wear increases with speed.
l Correct front wheel alignment is very important.
l Unbalanced wheels impair tire economy and driving comfort.
l If tires are rotated, they must be kept on the same side of the vehicle \
so that they revolve in the same
direction as before rotation.
l Hitting curbs or potholes can damage the tires and/or wheels permanently\
.
Flat spots
All tires become warm during use. After cooling, when the vehicle is par\
ked, the tires have a tendency to
distort slightly, forming flat spots. These flat spots can cause vibrati\
ons similar to the vibrations caused
by unbalanced wheels. They do, however, disappear when the tire warms up\
. The degree to which flat
spots form depends on the type of cord used in the tire. In cold weather\
, it takes longer for the tire to
warm up and consequently longer for the flat spot to disappear.
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2003 VOLVO XC90

Returning the spare wheel to its storage compartment
NOTE: The space under the vehicle is designed to hold the special spare wheel \
only. Other fullsize
wheels will not fit in this compartment.
Returning the spare wheel to the storage compartment
1. Use the crank (turn it counterclockwise) to lower the spare wheel's\
retaining cable.
2. Pass the toggle at the end of the cable through the center hole in th\
e spare wheel. Pivot the toggle 90
degrees so that when raised, the wheel will rest on the toggle.
3. Retract the retaining cable slightly by slowly turning the crank cloc\
kwise several times.
4. Position the wheel so that it is not obstructed by components in the \
exhaust system.
5. Continue to raise the wheel by turning the crank clockwise.Raise the \
wheel a little bit at a time and
guide it around the rear axle until it is securely seated in the storage\
area.
6. When it is no longer possible to turn the crank any further, check th\
at the spare wheel is securely in
position in the storage compartment.
pg. 120 Wheels and tires

Jack attachment points
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2003 VOLVO XC90
The fuel filter should be replaced at 120,000 miles (193,000 km). The \
filter is replaced as a complete
unit. Replace more frequently if contaminated fuel is introduced into th\
e tank, or if there is reason to
suspect that this has occurred.
Fuel system, including filler cap, tank, lines, and connections
The ability of the fuel system to contain hydrocarbons depends upon a le\
ak-free system. Inspect fuel
lines every 30,000 miles (48,000 km). Check for proper sealing of the \
fuel filler cap, which contains "O"
ring seals.
NOTE: If the fuel filler cap is not closed tightly or if the engine is running\
when the vehicle is refueled,
the Check Engine light (Malfunction Indicator) may indicate a fault. H\
owever, your vehicle's
performance will not be affected. Use only Volvo original or approved fu\
el filler caps.
Timing belt
For proper functioning of the engine and emission control systems, the t\
iming belt and belt pretensioner
must be replaced every 120,000 miles (193,000 km). Engine damage will \
occur if the belt fails.
PCV system
(on turbocharged models)
The nipple in the intake manifold and the filter at the end of the PCV h\
ose in the air cleaner should be
inspected and cleaned at 120,000 miles (193,000 km), and again at 150,\
000 miles (240,000 km).
Spark plugs
The spark plugs should be replaced every 60,000 miles (96,000 km) unde\
r normal driving conditions.
City driving or fast highway driving may necessitate replacement sooner.\
Under normal driving conditions, spark plugs require no maintenance betw\
een replacement intervals.
When installing new plugs, be sure to use the right type and to tighten \
them correctly. When changing
the plugs, clean the terminals and rubber seals. Also check that the sup\
pressor connectors are in good
condition. Cracked or damaged connectors should be replaced.
pg. 126 Maintenance
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pg. 134 Maintenance
Battery Maintenance
The battery in your vehicle is located under the floor of the cargo comp\
artment.
Driving habits and conditions, climate, the number of starts, etc. all a\
ffect the service life and function of
the battery. In order for your battery to perform satisfactorily, keep t\
he following in mind:
l Check the fluid level in each cell in the battery every 24 months or eve\
ry 15,000* miles (24,000 km),
whichever is sooner. The fluid should be at the level shown in the illus\
tration above (A)**.
l Use a screw driver to open the caps and a flashlight to inspect the leve\
l.
l If necessary, add distilled water. The level should never be above the i\
ndicator (A**).
l The fluid level should be checked if the battery has been recharged.
l After inspection, be sure the cap over each battery cell is securely in \
place.
l Check that the battery cables are correctly connected and properly tight\
ened. Route ventilation hose
through opening in floor (see
page 135)
l Never disconnect the battery when the engine is running, for example whe\
n changing the battery.
l The battery should be disconnected from the vehicle when a battery charg\
er is used directly on the
battery.
l However, if the battery is being charged via the connecting points in th\
e engine compartment (see
page 102), the battery must be connected.
* More frequently in warm climates.
** The level indicator inside the battery could be designed in various w\
ays. See illustration.
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locking system's remote control to reactivate such features as the power\
windows, moonroof, courtesy
lighting, etc.
WARNING!
PROPOSITION 65 WARNING!
Battery posts, terminals, and related accessories contain lead and lead \
compounds, chemicals known
to the state of California to cause cancer and reproductive harm. Wash h\
ands after handling.
pg. 137 Maintenance
Bulbs
The following bulbs are used in the vehicle:
1. Low beam/high beam - 55W H7
2. Bi-Xenon headlight (option) - 35W D2R
3. Backup light - 21 W BA15
4. Brake light - 21W BA15
5. Turn signals, rear - PY21W(amber bulb)
6. Turn signals, front - H21W
7. Door step courtesy light/cargo area lighting - W5W
8. Vanity mirror - 1,2W
9. License plate lighting/parking light in headlight/side marker light, \
rear W5W
Side turn signal - W5W (amber bulb)
10. Fog lights, front - 55W H1
11. Fog light, rear - 21W BA5
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12. Parking lights, rear - P21/4W
l Never touch the glass of bulbs 1, 2, 3, 10 with your fingers. Grease and\
oils from your fingers
evaporate in the heat and will leave a deposit on the reflector, quickly\
damaging it.
l Bi-Xenon headlight bulbs (option) contain trace amounts of mercury. Th\
ese bulbs should always be
disposed of by an authorized Volvo retailer.
WARNING!
Bi-Xenon headlights (option) - due to the high voltage used by these h\
eadlights, these bulbs should
only be replaced by an authorized Volvo service technician.
pg. 138 Maintenance

Retaining pins
Replacing high/low beams/turn signal/parking light bulbs
The entire lamp housing must be lifted out when replacing these bulbs.
To lift out the lamp housing:
1. Switch off the ignition.
2. Open the hood.
3. Pull up the retaining pins (see the illustration above).
4. Lift out the lamp housing.
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CAUTION
- Do not touch the glass on the halogen bulbs with your fingers. Grease,\
oil, or any other impurities
can be carbonized onto the bulb and cause damage to the reflector.
- Be sure to use bulbs of the correct type and voltage.
Location of the bulbs in the headlight housing
1. Low beam headlight/Bi-Xenon headlight (option)
2. High beam headlight
3. Turn signal
4. Parking light
5. Side marker light
pg. 139 Maintenance
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Replacing the low beam bulb
1. Remove the plastic cover over the bulb (1) by turning it counterclo\
ckwise.
2. Pull the connector from the lamp housing (2).
3. Loosen the bulb's retaining spring by first moving it to the right an\
d then moving it out of the way.
4. Pull out the bulb from the holder.
5. Insert the new bulb (without touching the glass) in the holder.
6. Move the retaining spring up and push it slightly to the left until i\
t seats properly.
7. Press the bulb holder into place on the headlight housing.
8. Reinstall the plastic cap. The letters "HAUT" on the cap must be upwa\
rd.
Replacing the high beam bulb
1. Remove the rubber cover over the bulb (1) by pulling it off.
2. Pull the connector from the lamp housing (2).
3. Loosen the bulb's retaining spring by first moving it to the right an\
d then moving it out of the way.
4. Pull out the bulb from the holder.
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5. Insert the new bulb (without touching the glass) in the holder.
6. Move the retaining spring up and push it slightly to the left until i\
t seats properly.
7. Press the bulb holder into place on the headlight housing.
8. Press the rubber cover into place.
Replacing the parking light/side marker light bulbs
1. Turn the lamp holder approximately 1/4 turn counterclockwise and pull\
it out of the headlight housing.
2. Pull the bulb straight out.
3. Align the guide lugs on the side of the base of the new bulb in the g\
rooves in the holder and press it
into place.
4. Press the lamp holder into the place in the headlight housing and tur\
n it approximately 1/4 turn
clockwise.
pg. 140 Maintenance
Bulbs (contd)
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