2003 Volvo XC90 Base, FWDFACTORY OEM SERVICE PROCEDURE

Explanation Of Dimensions

Fig 1: Body Dimension Measuring Point Symbols
GLL103313Courtesy of VOLVO CARS CORPORATION

The dimensions in the table are listed as follows:

Symbol number 1 means that the measurement is taken from the center.

Symbol number 2 means that the measurement is taken from one edge.

GLL103386Courtesy of VOLVO CARS CORPORATION

Symbol number 3 means that the measurement is taken from a cut mark. Measurements are taken from the bottom of the recess as shown.

If only one measuring point symbol is displayed, the symbol applies to both measuring points. Otherwise the symbols are shown on each side of the dimension shown.

Fig 2: Front Door Opening Measurement Locations (1 Of 2)
GLL103383Courtesy of VOLVO CARS CORPORATION

D1 = 946 mm

Fig 3: Front Door Opening Measurement Locations (2 Of 2)
GLL103384Courtesy of VOLVO CARS CORPORATION

D2 = 918 mm

D3 = 1351 mm

Fig 4: Rear Door Opening Measurement Locations
GLL103385Courtesy of VOLVO CARS CORPORATION

D4 = 1046 mm

D5 = 1150 mm

Fig 5: A-Pillar And B-Pillar Position Measurement Locations
GLL103389Courtesy of VOLVO CARS CORPORATION

E1 = 1446 mm

E2 = 1276 mm

E3 = 1546 mm

Fig 6: A-Pillar And Side Sill Position Measurement Locations
GLL103390Courtesy of VOLVO CARS CORPORATION

E4 = 1570 mm

E5 = 1478 mm

E6 = 1478 mm

Fig 7: B-Pillar, C-Pillar, And Side Sill Position Measurement Locations
GLL103391Courtesy of VOLVO CARS CORPORATION

E7 = 1307 mm

E8 = 1342 mm

E9 = 1490 mm

E10 = 1478 mm

Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.