2 0 0 3

Chapter 8 - Maintenance/Servicing

pg. 115 Maintenance/Servicing

Fuses 116
Replacing bulbs 120
Paint touch up 126
Washing the car 127
Cleaning the upholstery 128
Maintenance service, Warranty 129
Fuel/emissions systems 130
Drive belt, Air pump system, Coolant 131
Emissions maintenance 132
Washer fluid reservoir, Hoisting the car 133
Opening the hood, Engine compartment 134
Engine oil 135
Power steering/Brake fluid reservoirs 137
Battery maintenance 138
Replacing wiper blades 140

pg. 116 Fuses

Replacing fuses

If an electrical component fails to function, it is possible that a fuse has blown due to a temporary circuit overload.

Fuses are located in different places:

A - Relays/fuse box in the engine compartment
B - Fuse box in the passenger compartment
C - Relays/fuse box in the cargo area

A label on the inside of each cover indicates the amperage and the electrical components that are connected to each fuse.

The easiest way to see if a fuse is blown is to remove it. Pull the fuse straight out. If a fuse is difficult to remove, you will find a special fuse removal tool in the passenger compartment fuse box. From the side, examine the curved metal wire to see if it is broken. If so, put in a new fuse of the same color and amperage (written on the fuse). Spare fuses are stored in the fuse box in the passenger compartment. If fuses burn out repeatedly, have the electrical system inspected by an authorized Volvo retailer.

Never use fuses with higher amperage that those stated on the following pages. Doing so could overload the car's electrical system.

pg. 117 Fuses in the engine compartment

Relays/fuses in the engine compartment

When replacing fuses, be sure to replace a blown fuse with a new one of the same color and amperage (written on the fuse). Fuse amperage is also indicated on the inside of the fuse box cover.

A - To open, press the plastic catches on the rear side of the fuse box cover and lift

Ordinary fuses

Location Amperage
1 Accessories 25A
2 Auxiliary lamps (option) 20A
3 Vacuum pump 15A
4 Oxygen sensors 20A
5 Crankcase ventilation heater, solenoid valves 10A
6 Mass airflow sensor, engine control module, injectors 15A
7 Throttle module 10A
8 AC compressor, accelerator pedal position sensor, E-box fan 10A
9 Horn 15A
10 Tailgate wiper 10A
11 AC compressor, ignition coils 20A
12 Brake light switch 5A
13 Windshield wipers 25A
15 -
16 Windshield washers, headlight wiper/washers (certain models) 15A
17 Low beam, right 10A
18 Low beam, left 10A
20 High beam, left 15A
21 High beam, right 15A
22 Starter motor 25A
23 Engine control module 5A
24 -

pg. 118 Fuses in the passenger compartment

Fuse box in the passenger compartment

This fuse box is located at the far left side of the instrument panel. Extra fuses and the fuse removal tool are also stored here. When replacing a blown fuse, be sure to replace it with a new one of the same color and amperage (written on the fuse).
Location Amperage
1 Low beam headlights 15A
2 High beam headlights 20A
3 Power driver's seat 30A
4 Power passenger's seat 30A
5 -
6 -
7 Heated seat - front left (option) 15A
8 Heated seat - front right (option) 15A
10 -
11 -
12 Headlight wipers (certain models) 15A
13 Electric socket 12 V 15A
14 Power passenger's seat 5A
15 Audio system, VNS 5A
16 Audio system 20A
17 Audio amplifier 30A
18 Front fog lights 15A
19 VNS display 10A
20 -
21 Automatic transmission, shiftlock, extended D2 feed 10A
22 Direction indicators 20A
23 Headlight switch module, climate control system, onboard diagnostic connector, steering wheel lever modules 5A
24 Relay for extended D1 feed: climate control system, power driver's seat, driver's info 10A
25 Ignition switch, relay starter motor, SRS, engine control module 10A
26 Climate control system blower 30A
27 -
28 Electronic module - courtesy lighting 10A
29 -
30 Left front/rear parking lights 7.5A
31 Right front/rear parking lights, license plate lights 7.5A
32 Central electrical module, vanity mirror lighting, power steering,
glove compartment light, interior courtesy lighting
33 Fuel pump 15A
34 Power sun roof 15A
35 Central locking system, power windows - left door mirror 25A
36 Central locking system, power windows - right door mirror 25A
37 Rear power windows, power child safety 30A
38 Alarm siren 5A

* Please be aware that if this fuse is not intact, or if it is removed, the alarm will sound.

pg. 119 Fuses in the cargo area

Fuses in the cargo area

The fuses in the cargo area are located on the trim on the left-hand side. When replacing a blown fuse, be sure to replace it with a new one of the same color and amperage (written on the fuse).

Ordinary fuses

Location Amperage
1 Rear electrical module, cargo area lighting 10A
2 Rear fog light 10A
3 Brake lights 15A
4 Backup lights 10A
5 Rear window defroster, relay 15I - accessories 5A
6 Unlocking tailgate 10A
7 Auxiliary 12 volt socket in cargo area (option) 15A
8 Central locking rear doors/fuel filler door 20A
9 Trailer (30 feed) 15A
10 CD changer, VNS 10A
11 Accessory control module (AEM) 15A
12 Tailgate wiper 15A
13 Loudspeaker (subwoofer) cargo area - option 15A
14 Brake lights7.5A
15 Trailer (15I feed) 20A
16 -
17 All Wheel Drive control module 7.5A
18 -

pg. 120 Replacing bulbs

Replacing high/low beam headlight bulbs

The headlight bulbs must be replaced from the engine compartment.


  • Do not touch the glass on 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.

    Removing a defective bulb

    To remove a defective low beam bulb:

  • Switch off all lights and turn the ignition switch to position 0.
  • Open the hood.
  • Remove the plastic cover over the bulb (1) by turning it counterclockwise.
  • Remove the connector (2).
  • Loosen the retaining spring (3) by first moving it to the right and then moving it down, out of the way.
  • Pull out the defective bulb. Note the position of the guide lug on the base of the bulb (4).

    Installing a new bulb

    To install a new low beam bulb (H7):

  • Insert the new bulb, without touching the glass, with the guide lug upward (1). The bulb will only seat properly in this position.
  • Move the retaining spring up and push it slightly to the left until it seats properly (2).
  • Press the connector into place on the bulb (3).
  • Reinstall the plastic cover and turn it clockwise until it is correctly in place (4). "TOP" must be upward.

    NOTE: If the vertical aim of your headlights needs to be adjusted for any reason (e.g., towing a trailer for extended periods), this should be done by an authorized Volvo retailer.

    pg. 121 Replacing bulbs

    To remove and install a high beam bulb (HB3):

  • Switch off all lights and turn the ignition switch to position 0.
  • Open the hood.
  • Remove the cover by twisting it counterclockwise.
  • Twist the bulb holder counterclockwise, pull it out and fit a new bulb. Note its position.
  • Refit the bulb holder. It can only be fitted in one way.
  • Screw the cover back on. The word TOP should be upwards.

    Replacement of front parking light bulb

  • Switch off all lights and turn ignition key to position 0.
  • Remove the low beam cover by twisting counterclockwise.
  • Pull out the bulb and its socket. Replace bulb.
  • Press the bulb and its socket back into place.
  • Check that the new bulb lights.
  • Screw the cover back into place, "TOP" should be upwards!

    Changing the bulb in the turn signals at the front corners

  • Switch off all lights and turn ignition key to position 0.
  • Pull out the bulb and its socket by twisting counterclockwise. Replace bulb.
  • Press the bulb and its socket back into place.
  • Check that the new bulb lights.

    pg. 122 Replacing bulbs

    Replacement of bulbs in backup light, rear parking lights and rear fog lights

  • Switch off all lights and turn the ignition switch to position 0.
  • Open the access panel.
  • Remove the sound insulation behind it.
  • Twist the bulb holder counterclockwise and remove it.
  • Press the bulb inward, twist it counterclockwise and extract it.
  • Fit a new bulb.
  • Fit the bulb holder in place and twist it clockwise.
  • Refit the sound insulation and put the access panel back in place.

    Replacement of rear turn signal and brake light bulbs

  • Switch off all lights and turn the ignition switch to position 0.
  • Using a screwdriver, carefully pry off the speaker grille.
  • Pull out the red tab in the speaker.
  • Then press on the black pin above the extracted red tab and twist out the speaker.
  • Twist the bulb holder counter-clockwise, and withdraw it.
  • Fit a new bulb.
  • Fit the bulb holder in place and twist it clockwise.
  • Refit the speaker and press in the red tab.
  • Press the speaker grille back into position.

    pg. 123 Replacing bulbs

    Front fog lights (option)

    Avoid touching the glass on the bulb with your fingers.

  • Switch off all lights and turn the ignition key to position 0.
  • Turn the bulb holder slightly counterclockwise to release it.
  • Replace the bulb. The shape of the base of the bulb corresponds to the shape of the bulb holder.
  • Reinstall the bulb holder by turning it slightly clockwise. "TOP" on the holder should be upward.

    Side direction indicator

  • Open the front door halfway.
  • From the inside of the fender, push the lamp housing out.
  • Turn the bulb holder 1/4 turn counterclockwise and pull it out from the lens.
  • Remove the defective bulb by pulling it straight out.
  • Insert a new bulb.
  • Reinsert the bulb holder in the lens and press the entire unit back into place on the fender.

    Door step courtesy lights

    The door step courtesy lights are located under the dash on the driver's and passenger's sides.
    To replace a bulb:
  • Carefully insert a screwdriver and pry out the lens.
  • Replace the defective bulb.
  • Reinstall the lens.

    pg. 124 Replacing bulbs

    License plate lights

  • Switch off the ignition.
  • Loosen the screws with a Torx screwdriver.
  • Carefully pull out the lamp housing.
  • Turn the bulb holder counterclockwise and pull it out.
  • Pull out the defective bulb and insert a new one.
  • Reinsert the bulb holder into the housing and turn it clockwise.
  • Reinstall the housing and screw it in place.

    Vanity mirror lights

  • Carefully insert a screwdriver and pry out the lens.
  • Pry out the defective bulb and replace it.
  • Carefully press the lower edge of lens onto the four tabs and press the upper edge of the lens into place.

    Front courtesy lights

    These bulbs may be difficult for you to replace yourself. We recommend that you let an authorized Volvo retailer replace these bulbs if necessary.

    pg. 125 Replacing bulbs

    Rear reading lights

    These bulbs may be difficult for you to replace yourself. We recommend that you let an authorized Volvo retailer replace these bulbs if necessary.

    NOTE: Other bulbs may be difficult for you to replace yourself. Let an authorized Volvo retailer replace these bulbs if necessary.

    pg. 126 Paint touch up

    Paint touch-up

    Paint damage requires immediate attention to avoid rusting. Make it a habit to check the finish regularly - when washing the car for instance. Touch-up if necessary.

    Paint repairs require special equipment and skill. Contact your Volvo retailer for any extensive damage.

    Minor scratches can be repaired by using Volvo touch-up paint.

    NOTE: When ordering touch-up paint from your Volvo retailer, use the paint code indicated on the model plate. The plate is located in the engine compartment.

    Minor stone chips and scratches

    Primer - can
    Paint - touch-up bottle
    Masking tape

    NOTE: When touching up the car, it should be clean and dry. The surface temperature should be above 60° F (15° C).

    Minor scratches on the surface

    If the stone chip has not penetrated down to the metal and an undamaged layer of paint remains, the touch-up paint can be applied as soon as the spot has been cleaned.

    Deep scratches

    1. Place a strip of masking tape over the damaged surface. Pull the tape off so that any loose flakes of paint adhere to it.

    2. Thoroughly mix the primer and apply it with a small brush.
    When the primer surface is dry, the paint can be applied using a brush. Mix the paint thoroughly; apply several thin paint coats and let dry after each application.

    3. If there is a longer scratch, you may want to protect surrounding paint by masking it off.

    pg. 127 Washing the car

    Washing the car

  • The car should be washed at regular intervals since dirt, dust, insects and tar spots adhere to the paint and may cause damage. It is particularly important to wash the car frequently in the wintertime to prevent corrosion, when salt has been used on the roads.
  • When washing the car, do not expose it to direct sunlight. Use lukewarm water to soften the dirt before you wash with a sponge and plenty of water, to avoid scratching.
  • Bird droppings: Remove from paintwork as soon as possible. Otherwise the finish may be permanently damaged.
  • A detergent can be used to facilitate the softening of dirt and oil.
  • A water-soluble grease solvent may be used in cases of sticky dirt. However, use a wash place equipped with a drainage separator.
  • Remove dirt from the drain holes in the doors and rocker panels.
  • Dry the car with a clean chamois.
  • Tar spots can be removed with kerosene or tar remover after the car has been washed.
  • A stiff-bristle brush and lukewarm soapy water can be used to clean the wiper blades. Frequent cleaning improves visibility considerably.
  • Wash off the dirt from the underside (wheel housings, fenders, etc.).
  • In areas of high industrial fallout, more frequent washing is recommended.

    During high pressure washing, the spray mouthpiece must never be closer to the vehicle than 13" (30 cm). Do not spray into the locks.
    Special sun roof cautions:
    - Always close the sun roof and sun shade before washing your vehicle.
    - Never use abrasive cleaning agents on the sun roof.
    - Never use wax on the rubber seals around the sun roof.

  • When washing or steam cleaning the engine, avoid spraying water or steam directly on the electrical components or toward the rear side of the engine.
  • After cleaning the engine, the spark plug wells should be inspected for water and blown dry if necessary.

    Suitable detergents: Special car washing detergents should be used. Mix according to manufacturer's instructions.

    Bumpers: The bumpers are painted. Wash the bumpers with the same cleaning agent used on the rest of the car. Never clean the bumpers with gasoline or paint thinner. Difficult spots can be removed with denatured alcohol. To avoid scratches, do not dry the bumpers with paper.


  • When the car is driven immediately after being washed, apply the brakes several times in order to remove any moisture from the brake linings.
  • Engine cleaning agents should not be used when the engine is warm. This constitutes a fire risk.

  • pg. 128 Washing the car, Cleaning the upholstery

    Automatic washing - simple and quick

  • We do NOT recommend washing your car in an automatic wash during the first six months (because the paint will not have hardened sufficiently).
  • An automatic wash is a simple and quick way to clean your car, but it is worth remembering that it may not be as thorough as when you yourself go over the car with sponge and water. Keeping the underbody clean is most important, especially in the winter. Some automatic washers do not have facilities for washing the underbody.
  • Before driving into an automatic wash, make sure that side view mirrors, auxiliary lamps, etc, are secure, otherwise there is risk of the machine dislodging them.

    Polishing and waxing

  • Normally, polishing is not required during the first year after delivery. However, waxing may be beneficial.
  • Before applying polish or wax the car must be washed and dried. Tar spots can be removed with kerosene or tar remover. Difficult spots may require a fine rubbing compound.
  • After polishing, use liquid or paste wax.
  • Several commercially available products contain both polish and wax.
  • Waxing alone does not substitute for polishing of a dull surface.
  • A wide range of polymer-based car waxes can be purchased today. These waxes are easy to use and produce a long-lasting, high-gloss finish that protects the bodywork against oxidation, road dirt and fading.
  • Do not polish or wax your car in direct sunlight (the surface of the car should not be warmer than 113° F (45° C).

    Cleaning the upholstery

  • The fabric can be cleaned with soapy water or a detergent. For more difficult spots caused by oil, ice cream, shoe polish, grease, etc., use a clothing/fabric stain remover.
  • The plastic in the upholstery can be cleaned with a soft cloth and mild soap solution.
  • 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.
  • Under no circumstances should gasoline, naphtha or similar cleaning agents be used on the plastic or the leather since these can cause damage.

    Cleaning the seat belts

    Clean only with lukewarm water and 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 with a mild detergent.

    Stain removal

  • Take extra care when removing stains such as ink or lipstick since the coloring can spread.
  • Use solvents sparingly. Too much solvent can damage the seat padding.
  • Start from the outside of the stain and work toward the center.

    pg. 129 Maintenance service, Warranty

    Maintenance service

    Volvo advises you to follow the service program outlined in the Warranty and Service Records Information booklet. This maintenance program contains inspections and services necessary for the proper function of your car. The maintenance services contain several checks which require special instruments and tools and therefore must be performed by a qualified technician. To keep your Volvo in top condition, specify time-tested and proven Genuine Volvo Parts and Accessories.

    The Federal Clean Air Act - U.S.

    The Federal Clean Air Act requires vehicle manufacturers to furnish written instructions to the ultimate purchaser to assure the proper servicing and function of the components that control emissions. These services, which are listed in the "Warranty and Service Records Information booklet," are not covered by the warranty. You will be required to pay for labor and material used.

    Maintenance services

    Your Volvo passed several major inspections before it was delivered to you, in accordance with Volvo specifications. The maintenance services outlined in the Warranty and Service Records Information booklet, many of which will positively affect your vehicle's emissions, should be performed as indicated. It is recommended that receipts for vehicle emission services be retained in case questions arise concerning maintenance.

    Inspection and service should also be performed anytime a malfunction is observed or suspected.

    Page 128 provides information about maintenance of emission-related components.

    Applicable warranties - U.S.

    In accordance with applicable U.S. and Canadian regulations, the following list of warranties is provided.
  • New Car Limited Warranty
  • Parts and Accessories Limited Warranty
  • Corrosion Protection Limited Warranty
  • Seat Belt and Supplemental Restraint Systems Limited Warranty
  • Emission Design and Defect Warranty
  • Emission Performance Warranty

    These are the Federal warranties; other warranties are provided as required by state/provincial law. Refer to your separate Warranty and Service Records Information booklet for detailed information concerning each of the warranties.

    Previous Page   Next Page

    Contents | Top of Page