Volvo XC60 & XC90 Diesel 2003 – 2013 (Mol5630)


Volvo XC60 & XC90 Diesel Repair Manual 2003 – 2013

The Online Manual is not a printed product, not a PDF and not a download. Valid for 36 Months

Access this manual immediately on your internet browser on your mobile, desktop or tablet.

Videos included with this online manual

  • Pollen filter replacement
  • Headlight bulbs replacement
  • Battery removal & replacement
  • Front brake pads replacement
  • Fuel filter replacement
  • Rear light cluster bulbs replacement
  • Coolant replacement
  • Fluid level checks
  • Roadside wheel change
  • Air filter change
  • Engine oil and filter change
  • Wiper blade replacement
  • Rear brake pads replacement
  • Rear shock absorber replacement

What’s covered

What’s covered:


Volvo XC60 2.0L (1984cc) (2003 – 2013)
Volvo XC90 2.0L (1984cc) (2003 – 2013)
Volvo XC60 2.4L (2400cc) (2003 – 2013)
Volvo XC90 2.4L (2400cc) (2003 – 2013)
Volvo XC60 2.4L (2401cc) (2003 – 2013)
Volvo XC90 2.4L (2401cc) (2003 – 2013)

Includes 2WD and 4WD models


Does not cover petrol engines.

Table of contents

Safety First! Roadside repairs Weekly checks
Chapter 1 : Routine maintenance and servicing
Chapter 2A : Engine in-car repair procedures
Chapter 2B : Engine removal and overhaul procedures
Chapter 3 : Cooling, heating and air conditioning systems
Chapter 4A : Fuel and exhaust systems
Chapter 4B : Emission control systems
Chapter 5 : Starting and charging systems
Chapter 6 : Clutch
Chapter 7A : Manual transmission
Chapter 7B : Automatic transmission
Chapter 8A : Driveshafts
Chapter 8B : Transfer box, propeller shaft and final drive
Chapter 9 : Braking system
Chapter 10 : Suspension and steering
Chapter 11 : Bodywork and fittings
Chapter 12 : Body electrical systems Wiring diagrams Reference

Online manual

More details
Part number: MOL5630
Language: English
UPC: 699414011964

With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.

Key features:

  • All colour step-by-step guides for over 200 jobs with 700+ photos
  • Image zoom feature for close-up view of jobs
  • Brand-new “how to” video tutorials covering key repair tasks
  • Print complete sections to take with you into the workshop
  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
  • Easy search feature – find your job fast
  • Dictionary of automotive terms
  • Quick links to popular DIY tasks and other jobs linked to your task
  • Conversion calculator – imperial and metric units


The Volvo XC90 was first introduced in June 2002 and was the Swedish firm’s first proper SUV. It was a huge hit from the outset, with long waiting lists – something previously unheard of for a Volvo. All XC90 models were four-wheel drive (AWD). Petrol engines consisted of a 2.5 five-cylinder turbo, a 2.9 T6 (increased to 3.2 from 2006) and a 4.4 V8. However, all of the petrol engines were discontinued in 2010. There was only one diesel engine – a 2.4 D5 – which had 163bhp from the outset, later increased to 200bhp, and it’s our pick of the range. The more powerful petrol engines were fitted with an automatic gearbox, while the 2.5 and the 2.4 D5 had a choice of manual or auto ’boxes. The XC90 came with seven seats as standard and plenty of equipment; alloy wheels, six airbags, ESP, rear parking sensors, electric windows and climate control were fitted to every model, with higher trims adding heated leather seats, bigger alloys and auto lights and wipers. At Haynes, we have an extensive range of Volvo repair manuals and online maintenance procedures available for professional mechanics and DIY car enthusiasts. Our Volvo XC90 repair manual is here to help you through every stage of servicing or fixing your car.

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