2003 Volvo XC90 diesel: common problems and MOT failures

What goes wrong more than usual on a 2003 Volvo XC90 diesel?

Parts flagged at MOT more often on the 2003 Volvo XC90 diesel than on all cars registered in 2003.

• Suspension arm bushes and joints3.2× usual
  Volvo XC90

  27.3% All 2003 cars

  8.6%

  Failed outright at MOT: 5.2%, against 1.9% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £120–£180 (one arm) ClickMechanic

  At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

• Steering rack inner joints4.1× usual
  Volvo XC90

  13.8% All 2003 cars

  3.4%

  Failed outright at MOT: 0%, against 0% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £100–£450 our estimate

  At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

• Sub-frame3× usual
  Volvo XC90

  13.9% All 2003 cars

  4.7%

  Failed outright at MOT: 0.7%, against 0.3% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £300–£1,000 our estimate

  At the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.

• Number plate lights2.2× usual
  Volvo XC90

  16.9% All 2003 cars

  7.8%

  Failed outright at MOT: 5.2%, against 2.2% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £5–£40 our estimate

  At the viewing: Check the number plate lights work and the plates are clean and legal.

• Headlights1.8× usual
  Volvo XC90

  20.5% All 2003 cars

  11.7%

  Failed outright at MOT: 6.1%, against 4.6% of all 2003 cars. The rest were advisories or minor defects.

  Rough price £40–£400 our estimate

  At the viewing: Check both headlights on dipped and full beam, and look for cloudy or cracked lenses.

Common 2003 Volvo XC90 diesel MOT failures and advisories

The share of 2003 Volvo XC90 diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  62% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Lights and electrics
  48% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Brakes
  43% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Tyres
  31% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  20% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Steering
  17% of testsRough price £100–£450

  At the viewing: On a straight road the steering wheel should sit straight. Feel for play or knocking when turning.

Known faults on the 2003 Volvo XC90 diesel

Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.

• Geartronic gearbox failure

  Automatic

  The Geartronic automatic can fail expensively, especially on cars that have towed heavily.

  At the viewing: After 30 minutes' driving, feel for clunks or odd changes.

  Source: Parkers: Volvo XC90 (2002-2014) used review

• Timing belt tensioners and injectors (D5 diesel)

  D5 diesel

  D5 diesels can throw their belts if the tensioners and pulleys aren't renewed (Parkers suggests around 60,000 miles), and injectors can fail expensively.

  At the viewing: Ask for timing belt invoices, and look for smoke, erratic revs or poor starting.

  Source: Parkers: Volvo XC90 (2002-2014) used review

• Four-wheel-drive angle gear failure

  AWD

  The angle gear and sleeve can fail, leaving it in two-wheel drive.

  At the viewing: Ask a specialist to check the four-wheel-drive system.

  Source: Parkers: Volvo XC90 (2002-2014) used review

• Suspension, power steering and brakes

  All engines

  It's hard on suspension parts, the power steering pump can leak, and brakes wear quickly.

  At the viewing: Listen for knocks, turn lock to lock, and test the handbrake.

  Source: Parkers: Volvo XC90 (2002-2014) used review

• Electrical faults from water

  All engines

  A pollen filter cover fault can let water into the electrics.

  At the viewing: Test every electrical item.

  Source: Parkers: Volvo XC90 (2002-2014) used review

Questions to ask the seller before buying a 2003 Volvo XC90 diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Has the gearbox fluid been changed, and has it towed?
2. When were the timing belt and tensioners changed?
3. Any recent work on the suspension arm bushes and joints? (Flagged at MOT 3.2× as often on the 2003 Volvo XC90 diesel as on other cars the same age.)
4. Any recent work on the steering rack inner joints? (Flagged at MOT 4.1× as often on the 2003 Volvo XC90 diesel as on other cars the same age.)
5. Any recent work on the sub-frame? (Flagged at MOT 3× as often on the 2003 Volvo XC90 diesel as on other cars the same age.)
6. Can I see the service history and receipts for any big jobs?