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2003 Volvo XC90 Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
12/21/17 NHTSA ID: 10126648
TSB ID: FSB 262-005

Coolant bypass housing seal
12/21/17 NHTSA ID: 10126660
TSB ID: FSB 293-026

Exhaust gas recirculation (egr) differential pressure sensor
12/21/17 NHTSA ID: 10126631
TSB ID: FSB 293-024

Exhaust gas recirculation (egr) differential pressure sensor
12/21/17 NHTSA ID: 10126636
TSB ID: FSB 293-012

Exhaust gas recirculation, part update
08/03/17 NHTSA ID: 10110147
TSB ID: SMB22-206

All new volvo engines leave the factory filled?with castrol edge professional as an integral part of their delivery of high performance.?castrol edge professional?s outstanding?performance has made it the oil of choice for?volvo and is the
04/13/12 NHTSA ID: 10043584
TSB ID: TJ-16840

Software download may cause the brake control module (bcm) to make a diagnostic trouble code (dtc) of 0076 or on the xc90 dtc 0117 which also may accompany bcm dtc 0076. this is on vehicles equipped with dynamic stability traction control s
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06/01/11 NHTSA ID: 10037649
TSB ID: TJ-6438-5

Volvo: yaw rate sensor is outside of permitted range.
11/22/10 NHTSA ID: 10034505
TSB ID: TJ-19883

Volvo: snow in fan motor. blower fan/does not work. blower fan/unusual noise. snow may enter into the fan motor area due to heavy snowstorms.
11/07/08 NHTSA ID: 10026550
TSB ID: RTJ-18513

Volvo: angle gear leakage and resealing for 5 cylinder awd only vehicles. oil leaking/moisture fromthe angle gear halves can be resolved by resealing the houseing and replacing the seals.
10/02/08 NHTSA ID: 10026143
TSB ID: 28-200

Volvo: extend warranty coverage for the engine management software (ems) on some model year 2003-2008 models. p45 csc letter was received. ref: 10026144 (p-46), 10026145 (p-54), 10026146 (p-55), 10026147 (p-76). updated 6
04/16/08 NHTSA ID: 10024466
TSB ID: 46-13

5 cylinder angle gear leakage and resealing. on all wheel drive models. *nj updated 6/5/08. *nj
01/22/08 NHTSA ID: 10023657
TSB ID: 23-31

New fuel pump for starting problems when parked downhill. *nj updated 6/5/08. *nj
09/12/07 NHTSA ID: 10022612
TSB ID: 28-74

Leakage diagnostic function improvements to remedy dtc's. updated 1/22/08. *nj updated 4/7/08. *nj
09/12/07 NHTSA ID: 10022614
TSB ID: 6417

Power steering fluid leak at reservoir.
09/12/07 NHTSA ID: 10022619
TSB ID: 168

Plastic nipple of the positive crank ventilation (pcv) system may crack or become loose. this could result in an air leak from the crank case ventilation system. this may cause a whistling noise or check engine light may illuminate.
08/03/07 NHTSA ID: 10022342
TSB ID: 5914

Bcm dtc 0091, active yaw control sensor damper.
08/22/06 NHTSA ID: 10020262
TSB ID: 5913

Follow the complete diagnostic fault-tracing path outlined in vida when repairing diagnostic trouble codes (dtc's) related to the brake control system.
08/22/06 NHTSA ID: 10020265
TSB ID: 6109

Ball joint replacement, new method & tools.
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07/21/06 NHTSA ID: 10020113
TSB ID: 6421

Steering noise, yoke adjustment. knocking, thumping, or clicking noise may be heard from the steering.
09/27/05 NHTSA ID: 10016700
TSB ID: 6107

Front control arm bushing replacement. *sc
09/26/05 NHTSA ID: 10016668
TSB ID: 7206

Rear suspension popping/spring noise. to include volvo xc90 1999-2000. *sc
08/31/05 NHTSA ID: 10016113
TSB ID: 6420

Zf power steering diagnostics on vehicles equipped (ecps) electronically controlled power steering.
05/04/05 NHTSA ID: 10014585
TSB ID: 08012004

Vacuum hose routing label. *eh
11/24/04 NHTSA ID: 10010475
TSB ID: 5503

Parking brake pedal and primary cable replacement.
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11/23/04 NHTSA ID: 10010464
TSB ID: 113A

Lower cooling hose replacement. service upgrade. this tech note supercedes the previous tnn dated 2-25-03. service manager bulletin and retailer notification letter.
04/27/04 NHTSA ID: 10006259
TSB ID: 0051

Vvt solenoid, cleaning. *mr
04/26/04 NHTSA ID: 10006215
TSB ID: 0038

Replacing the hose under the intake manifold. *mr
10/17/03 NHTSA ID: 10003396
TSB ID: 5502

Parking brake adjustment.
04/14/03 NHTSA ID: 10001077
TSB ID: 113

Lower radiator hose upgrade. service upgrade 113a - lower cooling hose replacement.
04/11/12 Transmission and Drivetrain NHTSA ID: 10043574
TSB ID: TJ-7319

Front left frost plug displacement can cause axle grease to mix with the automatic transmission fluid (atf).
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06/07/11 Transmission and Drivetrain NHTSA ID: 10037893
TSB ID: TJ-US16761

Volvo: there is a software update. updated 4/11/2012. updated 4/13/12. updated 5/15/12. updated 6/4/12.
06/07/11 Transmission and Drivetrain NHTSA ID: 10037896
TSB ID: US20756

Volvo: abs light on, four-wheel drive is not working. there is a software problem.
06/28/10 Transmission and Drivetrain NHTSA ID: 10033045
TSB ID: RTJ-22103

Volvo: rear differential housing, leakage and resealing. oil leakage/moisture from the rear differential housing halves can be resolved by resealing the housing and replacing the seals. the rear differential itself does not normally need
03/24/10 Transmission and Drivetrain NHTSA ID: 10032425
TSB ID: RTJ-21324

Volvo: the 5 speed automatic transmission, aw55-50/51, has a bolt on top that anchors the b4 band, which applies 3rd gear. if that bolt is removed, the band will be disengaged and 3rd gear will be inoperative. this includes c70 coupe and
09/12/05 Transmission and Drivetrain NHTSA ID: 10016434
TSB ID: 4002

Transmission control module (tcm) upgrades available to correct complaints/symptoms.
11/23/04 Transmission and Drivetrain NHTSA ID: 10010468
TSB ID: 4342

Tcm sw upgrade, 2-3 upshift flare.
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10/23/03 Transmission and Drivetrain NHTSA ID: 10003549
TSB ID: 4341

Transmission control module (tcm) diagnostic trouble code (dtc) 0053, lock up pressure switch stuck. 2004 s80 included.
04/04/03 Transmission and Drivetrain NHTSA ID: 10000922
TSB ID: 43006

Some vehicles may set a 002f code or have a slipping / shuddering (in 4th and/or 5th gear) torque converter.
02/05/18 Electrical and Air Conditioning NHTSA ID: 10128171
TSB ID: ST-001-2017-10-0

Mandatory tool list bulletin: volvo mandatory special tools are necessary for technicians to properly diagnose and repair volvo cars. they are used in development of volvo labor operations and repair methods, and promote safety and quality
02/05/18 Electrical and Air Conditioning NHTSA ID: 10128160
TSB ID: SMB00-337-2017-1

Volvo cars service and parts business service manager bulletin title : workshop systems requirements and guidelines vida in 2015 , peer - to - peer infrastructure group : no : issuing department : car market : united states and canada 00 33
02/05/18 Electrical and Air Conditioning NHTSA ID: 10128164
TSB ID: TJ25788 1 3-2017

Title blis fault tracing . status released status 2012 - ref no us25788.1.1 en - us date 04 - 16 issue 2012 - issuer - date 01 - 19 vida partner 3 us 7510 volvo cars north america reference func group 8462 func desc electrical outside mirro
02/05/18 Electrical and Air Conditioning NHTSA ID: 10128123
TSB ID: SMB00-325-2017-1

Service manager bulletin title : service action notification re - mails group : no : issuing department : car market : product safety & compliance united states and canada 00 325 reference bulletins : date : smb00 - 323 and smb00 - 323a yea
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01/22/18 Electrical and Air Conditioning NHTSA ID: 10127330
TSB ID: TJ2753672

This document is a technical journal: information about valid software partnumbers to order and download software for "pds" pre-delivery service
12/21/17 Electrical and Air Conditioning NHTSA ID: 10126616
TSB ID: FSB 284-046

Instrument cluster reported fuel economy calibration
12/21/17 Electrical and Air Conditioning NHTSA ID: 10126666
TSB ID: FSB 284-059

Nox sensor signal
08/03/17 Electrical and Air Conditioning NHTSA ID: 10110167
TSB ID: SPJ31628.7.0

Vida users are not able to check operations & packages an error message will be shown saying "database error. please contact system administrator"
08/03/17 Electrical and Air Conditioning NHTSA ID: 10110168
TSB ID: SPJ31721.1.0

Below error message may be shown in vida when selecting the software tab in vida. with this message, it will not be possible to purchase software products. "124 - client id is not registered"
08/03/17 Electrical and Air Conditioning NHTSA ID: 10110166
TSB ID: SPJ31352.1.0

Alternative solution when vida is unavailable or the electronic wiring diagrams function in vida is unstable. access by using the applicable url.
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08/03/17 Electrical and Air Conditioning NHTSA ID: 10110169
TSB ID: SPJ31722.1.1

A new feature will be available in vida version 16.4 where by users will be automatically informed when their passwords are about to expire. the pop-up window example, in the attachment, will be shown 14 days prior to the expiraton date.
08/03/17 Electrical and Air Conditioning NHTSA ID: 10110151
TSB ID: TJ27536

Information about valid software partnumbers?to order and download software for "pds" pre-delivery service
01/13/17 Electrical and Air Conditioning NHTSA ID: 10088666
TSB ID: TJ31543

This is a technical journal: this journal is a guide for performing software downloads. service: *see guide updated oct. 12, 2016 for relevant p5/spa software download information: p5_spa_sw_guide.pdf see vida software tab for all other veh
12/22/16 Electrical and Air Conditioning NHTSA ID: 10087107
TSB ID: SPJ3070120160419

This is a service product journal : the previously reported issue with vida 2015 and battery testing has been resolved. vida 2015 battery testing is the only approved method for producing battery test codes. the use of vida classic or other
08/06/13 Electrical and Air Conditioning NHTSA ID: 10052500
TSB ID: SB-49325

Select document search button for owner letter. volvo: on some vehicles, the software for transmission control module (tcm) fails to contain optimal calibration settings, and would need to install upgraded tcm software. models 2003-2005
04/12/13 Electrical and Air Conditioning NHTSA ID: 10051798
TSB ID: TJ 27303

Headlamp moisture due to broken guide pin. volvo.
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06/06/11 Electrical and Air Conditioning NHTSA ID: 10037818
TSB ID: TJ-11297-4

Volvo: with vehciles that have high miles there may be an air bag light on with trouble codes stored.
09/24/09 Electrical and Air Conditioning NHTSA ID: 10030359
TSB ID: RTJ-16629

Volvo: leakage detection diagnostics improvements to remedy dtc's. all models from model years 2003-2008. diagnostic monitor for the evaporative emission system small leak, has used a software function that calculates leakage based on a pr
01/12/09 Electrical and Air Conditioning NHTSA ID: 10027285
TSB ID: RTJ-19254

Volvo: headlamp low beam connector replacement. a new method of repair for halogen type low-beam headlamps has been developed to address complaints for vehicles. updated 3/27/09. updated 12/23/09.
01/11/06 Electrical and Air Conditioning NHTSA ID: 10018726
TSB ID: 8553

Air conditioning afterblow function. *ak
01/11/06 Electrical and Air Conditioning NHTSA ID: 10018732
TSB ID: 3002

Service campaign 135b - software upgrade.
12/09/05 Electrical and Air Conditioning NHTSA ID: 10017959
TSB ID: 135H

Service campaign 135h: excessive airflow on the top of the foot/ankle from the floor vent. may be more noticeable when the climate control module (ccm) is set to auto position.
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12/08/05 Electrical and Air Conditioning NHTSA ID: 10017956
TSB ID: 135C

Service campaign 135c: headlamp washer pump may cause increased electrical demand at low temperatures, even with sufficient washer fluid antifreeze. washers not functioning may be caused by blown fuse no. 15 in the engine compartment fuse
09/27/05 Electrical and Air Conditioning NHTSA ID: 10016674
TSB ID: 8526

Small fore and aft or rocking movement of the seat during accelerations nd deceleration might be experienced in certain cases.
08/31/05 Electrical and Air Conditioning NHTSA ID: 10016112
TSB ID: 3638

Rain sensor function.
08/31/05 Electrical and Air Conditioning NHTSA ID: 10016114
TSB ID: 8525

Mechanical front seats, adjusting seat slide rail locking position.
11/23/04 Electrical and Air Conditioning NHTSA ID: 10010469
TSB ID: 4343

Tcm sw upgrade, dtc 0099.
05/11/04 Electrical and Air Conditioning NHTSA ID: 10006704
TSB ID: 0026

Mass movement sensor module (mms) alarm, adjusting. this bulletin describes how to reduce the risk of false alarms caused by torrential rain.
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10/20/03 Electrical and Air Conditioning NHTSA ID: 10003403
TSB ID: 37117

Ground cable water intrusion. service manager bulletin. service upgrade 117.
10/15/03 Electrical and Air Conditioning NHTSA ID: 10003293
TSB ID: 3933

Additional fault tracing information for the xc90 infotainment system.
10/02/03 Electrical and Air Conditioning NHTSA ID: 10002971
TSB ID: 370020

Water intrusion into the ground lead cables may cause improper function of certain engine components - service upgrade 117.
04/30/03 Electrical and Air Conditioning NHTSA ID: 10001320
TSB ID: 116

Service upgrade - adjusting the steering column may affect the function of the immobilizer system.
03/13/18 Other NHTSA ID: 10130194
TSB ID: SMB00-337-2017-1

Volvo cars service and parts business service manager bulletin title : workshop systems requirements and guidelines vida in 2015 , peer - to - peer infrastructure group : no : issuing department : car market : united states and canada 00 33
03/13/18 Other NHTSA ID: 10130198
TSB ID: TJ25788 1 3-2017

Title blis fault tracing . status released status 2012 - ref no us25788.1.1 en - us date 04 - 16 issue 2012 - issuer - date 01 - 19 vida partner 3 us 7510 volvo cars north america reference func group 8462 func desc electrical outside mirro
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03/13/18 Other NHTSA ID: 10130264
TSB ID: SMB00-325-2017-0

Service manager bulletin title : service action notification re - mails group : no : issuing department : car market : product safety & compliance united states and canada 00 325 reference bulletins : date : smb00 - 323 and smb00 - 323a yea
03/13/18 Other NHTSA ID: 10130265
TSB ID: SMB00-288-2017-0

The warranty retailer counseling process (wrcp) is used to gauge individual retailer performance on objective measures over time. by setting clear performance expectations and parameters and assisting retailers in focusing on individual pro
03/13/18 Other NHTSA ID: 10130267
TSB ID: SMB00-354-2017-0

Warranty, customer pay and/or internal repairs performed must be verified by a punched time flag on the back of the repair order hard copy. each repair line must have a separate and identifiable time punch for the respective repair for all
02/26/18 Other NHTSA ID: 10129357
TSB ID: SERVICE INSTRUCT

Supplier service bulletin sent to customers regarding potential brake caliper issue.
02/20/18 Other NHTSA ID: 10129019
TSB ID: K91214678

Automated manual transmission ( amt ) faults - diagnostic trouble codes ( dtcs ) p1052 - 18 , pid 33 fmi 5 intermittent fault in cold weatherupdated with new information and procedure
02/05/18 Other NHTSA ID: 10128178
TSB ID: ST-001-2017-10-0

Mandatory tool list bulletin: volvo mandatory special tools are necessary for technicians to properly diagnose and repair volvo cars. they are used in development of volvo labor operations and repair methods, and promote safety and quality
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01/22/18 Other NHTSA ID: 10127322
TSB ID: PB77-017-2017-06

This is a parts bulletin: wheel cross reference, used to assist in identifying the correct spare replacement wheel, by stamping, name and size.
01/22/18 Other NHTSA ID: 10127339
TSB ID: SPJ3176020

This document is a service product journal: memory used for vida is not fully optimized and below examples of symptoms might therefore occur. vida will run slow after some time. vida might freeze. certain operations might stop working.?in
10/26/17 Other NHTSA ID: 10120954
TSB ID: PB77-006

Winter wheel applications including rim sizes, steel wheel parts numbers and wheel cover part numbers
08/03/17 Other NHTSA ID: 10110161
TSB ID: SMB00-325

*no description
08/03/17 Other NHTSA ID: 10110159
TSB ID: SMB-00-353

The volvo technical helpdesk (thd) is a central contact point available to authorized volvo dealer technicians to assist with difficult to repair situations. if for some reason our technical experts cannot solve an issue directly, it will b
08/03/17 Other NHTSA ID: 10110146
TSB ID: SMB88-001A

Seat belt extender
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08/03/17 Other NHTSA ID: 10110145
TSB ID: TJ19967

Blisters/bubbles may appear on the air vent?surfaces. the blistering of the material is often caused?by an air freshener applied directly to the air?vents. do not attach any sort of air freshener?directly on air vents.
08/03/17 Other NHTSA ID: 10110212
TSB ID: SPJ31593

There has been an increasing amount of?reports where users state that its not possible?to perform a vehicle readout when pressing ?connect? there will be an error message asking the user?if they wants to retry after an error message?saying
08/03/17 Other NHTSA ID: 10110183
TSB ID: TJ26745.7.2

This document is a technical journal: effective immediately, all 12v batteries may be?tested using the hand held battery tester 9513030 (bt3300). the vida test is still?available but no longer required. for battery replacements under warran
01/12/17 Other NHTSA ID: 10088566
TSB ID: SMB17-2017A

Volvo cars service and parts business service manager bulletin title : retail car delivery process all my 2016 s60 , v60 , xc60 , xc70 and s80 group : no:issuing department : car market : united states and canada 17 2016a service operations
01/11/17 Other NHTSA ID: 10088374
TSB ID: SMB00-354

Warranty, customer pay and/or internal repairs performed must be verified by a punched time flag on the back of the repair order hard copy. each repair line must have a separate and identifiable time punch for the respective repair for all
10/24/11 Other NHTSA ID: 10041668
TSB ID: SMB-88-001A

Volvo: for owners who require front seat belt extenders which are available.
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04/12/06 Other NHTSA ID: 10019643
TSB ID: 006

Pirelli tires - customer service tire warranty / canada.
02/09/06 Other NHTSA ID: 10019022
TSB ID: 013

Volvo recommended winter tires.
12/09/05 Other NHTSA ID: 10017960
TSB ID: 135I

Service campaign 135i: the seatbelts located in the 2nd row of seats may get caught in the door and possibly damage the door panels.
12/08/05 Other NHTSA ID: 10017957
TSB ID: 135G

Service campaign 135g: third row seat, non folding. when the bottom seat cushion is pushed inwards to fold the backrest, the plastic catch may crack and come loose from the attachment.
01/26/05 Other NHTSA ID: 10011529
TSB ID: 850036

Front seat, mechanical, adjusting. play/clearance/clicking at the lower mountings for the front height adjuster.
11/23/04 Other NHTSA ID: 10010465
TSB ID: 8333

The cable to release the upper tailgate may come loose from its mounting clip. tech note.
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09/02/04 Other NHTSA ID: 10008966
TSB ID: 2118

Sub frame squeaking noise.
07/19/04 Other NHTSA ID: 10007985
TSB ID: 135

Service campaign 135a-i for new and improved components.
07/07/04 Other NHTSA ID: 10007632
TSB ID: 135

Volvo has developed new and improved components to help ensure customer satisfaction. service campaign 135. *mj service campaign 135b.
02/17/04 Other NHTSA ID: 10005234
TSB ID: 82115

Hood alignment guide - service manager bulletin.
02/17/04 Other NHTSA ID: 10005235
TSB ID: 825

Hood alignment guide, service upgrade parts bulletin.
10/24/03 Other NHTSA ID: 10003602
TSB ID: 880034

New belt guide to prevent the locking tab of the outer seat belts for the 2nd row rear seat from catching in the door.
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10/17/03 Other NHTSA ID: 10003397
TSB ID: 8201

Service upgrade 115 - hood alignment guide.
06/04/03 Other NHTSA ID: 10001488
TSB ID: 8409

Excessive closing force required to shut the rear side doors.

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Volvo XC90 TSBs (Technical Service Bulletins)

Some things are often misunderstood about recalls and technical service bulletins (TSBs). Plus a disclaimer.

  1. Recalls do not have to be issued only because something is prone to failure. NHTSA (a government agency) can only require a recall if a failure will affect safety, emissions, fuel economy, or compliance with some other regulation or law. Manufacturers can voluntarily recall cars for problems that do not affect these, though.
  2. Recalls often apply to only some cars of a specific model year, rather than all of them. You should receive a letter from the manufacturer if your car has been recalled. You can also check with the dealer, which will know which (if any) recalls pertain to your car.
  3. The primary purpose of TSBs is to inform dealers about known problems with a car and how to fix them. They are not the same as recalls. As with recalls, TSBs often only apply to some cars, not the entire model year.
  4. Dealers often will not provide a preventive repair just because a problem described in a TSB might happen to your car. They'll usually want to observe symptoms that the problem is already affecting your car.
  5. Even if there are symptoms, a manufacturer doesn't have to pick up the cost of a TSB repair if the car is out of warranty, though sometimes they do.

We provide the text of recalls and TSBs as provided by NHTSA. There can be errors in the text. If you sign up for notifications in My Garage, we will try to get these to do, but for various reasons (some beyond our control) cannot guarantee you will receive them. When in doubt about a recall or TSB, contact the dealer.