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2003 XC90 the build/repairs/upgrade thread, Lots of pictures


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#1 Ghost Shadow

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Posted 23 October 2011 - 11:18 AM

In this thread i will show you what all has been done to my beloved XC90 from the first day i have acquired it, 143,000 Miles August 1,2010. I kinda had to buy it since its the same color as my convertible

First day after i bought it.
5% tint over the rear OEM tinted windows
5% tint on the front two windows
5% 9" front windshield tint band
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One of the first repairs were a ripped driver seat cushion, home made mod. so results were ok, no way am i a pro!
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Next up was getting rid of those NASTY fogged headlamps with new aftermarket OEM replacements. while i was at it, ehh threw some H7 6000k HID Low beams, yellow h7 high beams and modified the fog light housings to do H1 6000k Hidz
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Next was a remote start/alarm system. Who the hell wants to steal a XC90? NO ONE, but they would love to break into it and steal stuff out of it.
In went a CompuStar PRO 2 Way Rechargeable 1 mile paging system with optional Touch RPS panel, and battery backup. Also done at the same time Drone Mobile GPS tracking/SmartPhone interface device.
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Then came time for HIDz in in the reverse lights
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Then came 12 pieces of 24LED panels thru out the car. this is so bright
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I found a set of thin load bars on craigslist for $75 the guy took $50 and i had a Yakima Load Warrior cargo basket with the 33" extension from my old XC70.
so it went from this.
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to this
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Soon after, i found the need to do backup camera and video up front and AUX input because sirius coming thru FM modulated sucked, wanted bluetooth too.
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dis-assembled a OEM nav screen and put my own in there. My car did not come with nav
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Got a OEM Nav screen from erie vovo, got the Dension Gateway 500 and installed a left over Motorola IHF1000 bluetooth and used the speaker from the center channel as the bluetooth speaker. did a backup camera too
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Started getting the itch for more performance. Bad idea since i have a T6, but i figure a new exhaust never hurt anything. Since i put the tire in the cargo basket, i have alot of room for a DUAL exhaust! :)
ebay'd a obx exhaust, at that time got it for $425 delivered, i have been told its cheaper now.
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Here it is..
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Dont think i didnt do any maintenance or repairs/upgrades while i had it....Here's the first with the suspension
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H and R Lowering Springs, eliminated the rear Nivomats. it came with 4 springs and two rear shocks
before and after
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along with the springs i also did
  • both inner tie rods
  • both outer tie rods
  • IPD rear camber bushings (needed with the lowering)
  • both front lower control arms
  • both front sway bar end links
  • both front ball joints
  • steering rack (that broke later)
Since the tire went to the rack and there was a ton of space under the car as you can see in the above pictures. I had space for these
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and two of these
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5 gallon tank, dual 480 CFM Viair air pumps and a set of train horns. 5 hours later i had this under there
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I also toyed with the idea of making my XC90 a 6 passenger, i did....
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found out that fold the middle row down and dont pull out the bottom coushin for the third row, the kids would sit better in their recaro booster seats :)
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Then came time for brakes, i changed out the lines, the brake booster went, changed front and rear rotors and pads. theres a write up on the brake lines in DIY
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Did O2 Sensors too, not that it needed it. Just to get better gas mileage.
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Her first winter..
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Got a good deal on a set of OEM 18" Pegasus Wheels, but it needs to be bored out to 67.1MM
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Did a set of Nitto NT420s tires in 255/55/18 and took the grill apart and painted it flat black
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMG_20110508_143653.jpg
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMAG0142.jpg

Got bored one day and did LED lights, tinted the tails and did 2007 and newer tails too
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMG_20110502_194711.jpg
i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMAG0083.jpg
Did LED upper tails too
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMG_20110714_213314.jpg
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMG_20110714_213324.jpg
http://i216.photobuc...0714_213230.jpg
http://i216.photobuc...0712_163012.jpg

Changed out the fog lights i had on the rack for reverse for a set of Rigid Industries LED D2 Dually Fog Lights
http://i216.photobucket.com/albums/cc132/gshadow325/Volvo%20XC90%202003%20T6%20AWD/IMG_20110522_212859.jpg

Latest mod
Sirius Backseat TV, look for the write up in the audio section
http://i216.photobuc...1022_135610.jpg
http://i216.photobuc...0AWD/temp_2.jpg
http://i216.photobuc...%20AWD/temp.jpg
1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#2 Ihatespeedbumps

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Posted 23 October 2011 - 02:54 PM

Impressive to say the least. Your installs are super clean, really like the backup camera in the NAV screen
05 S60R
98 S70 T5M

#3 flyfishing3

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Posted 23 October 2011 - 03:51 PM

man, you pissed some people off at carlisle with those horns. lol

#4 Ghost Shadow

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Posted 23 October 2011 - 04:30 PM

yeah...thats why i am bringing the vert this time....those horns can get me in trouble LOLL
1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#5 Ian Carr

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Posted 24 October 2011 - 05:14 PM

You win, that thing is mean lookin
Ian Carr - 99' Volvo S70 T5M - 86' Porsche 944 Turbo - 88' Ford Festiva
Posted ImageBecause Race Car.
True CAI, Neptunes, XC bumper, iPd25mm rear sway, short shifter, front mount, ssqv, sweet license plate mounted in the engine bay, lowered, HD Endlinks.

#6 warrentt

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Posted 24 October 2011 - 05:49 PM

Very nicely done project. Love all the audio work on the car especially the in-car dvd and rear camera.

#7 Ghost Shadow

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Posted 25 October 2011 - 12:55 AM

forgot about this video i had
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1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#8 Ghost Shadow

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Posted 25 October 2011 - 01:11 AM

car got a new sirius tuner saturday LOL and a new 10.5" dvd overhead the 9" was just not big enough. i didnt have a 15" in stock or else i would have put that in instead :P
previous owner has some aholes install a 6.5" dvd overhead and the hole up there is HUGE, you can still see the imprint of the overhead and a little bit of the CUT UP headliner showing.
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1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#9 Fake-R

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Posted 25 October 2011 - 03:09 AM

Sell me your running boards plz.
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1996 850 Turbo
2007 XC90 V8

#10 Ghost Shadow

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Posted 26 October 2011 - 12:25 AM

 Fake-R, on 25 October 2011 - 03:09 AM, said:

Sell me your running boards plz.

as much as i hate them...i like the look they make
1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#11 n00bkiller944

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Posted 02 November 2011 - 06:27 AM

I really like your XC90 man!!! Looks super clean!

#12 jmx747

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Posted 03 November 2011 - 11:34 PM

i love every single thing you did to your xc, its absolutely gorgeous!

#13 RBoy8

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Posted 04 November 2011 - 12:14 AM

Sooo what you rolling on now, Steve? :P

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#14 Stormtrooper1

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Posted 04 November 2011 - 01:37 AM

I love the hacked factory NAV video solution.

#15 JVC

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Posted 04 November 2011 - 03:26 AM

I remember seeing that NAV screen on my dads S80 T6 and knew that something sick could be done with it... this sir... is that something sick!

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1998 S70 T5, 2002 S80 T6, 2005 XC90 2.5T


#16 Ghost Shadow

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Posted 04 November 2011 - 11:04 AM

 RBoy8, on 04 November 2011 - 12:14 AM, said:

Sooo what you rolling on now, Steve? :P

20" Porsche Cayenne Turbo wheels..
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i kid, i kid....rolling on these again

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1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#17 Stormtrooper1

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Posted 04 November 2011 - 02:48 PM

 Ghost Shadow, on 04 November 2011 - 11:04 AM, said:

i kid, i kid....rolling on these again

I'm assuming thats an old pic and the wheels didn't come with all the salt spray? :lol:

#18 Ghost Shadow

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Posted 04 December 2011 - 01:56 PM

 Stormtrooper1, on 04 November 2011 - 02:48 PM, said:

I'm assuming thats an old pic and the wheels didn't come with all the salt spray? :lol:

old pic old tires too,

now i have teh Nitto NT420s in 255/55/18 so much nicer tire than the old Hankook crap. Also have not been driving it....DAMN YOU 1998 v70 T5 Manual!

last few things done is the 6 passenger mod, did a relay to keep all 3 sets of HIDs on when i have the high beams on. So right now i can have 5 sets of lights on at the same time!! HIDz in low beams, high beams, fog lights, reverse lights, and LED reverse lights on the roof rack...

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now they in the third row so they can have stadium seating
1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq

#19 winnipegtibook

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Posted 06 January 2012 - 10:22 PM

amazing thread. any suggestions on preferred US-based vendors (web or real store) for OEM aftermarket headlights? my 90's were horribly fogged and i used the 3M kit as a stop gap measure. looking for new (and brighter) for the spring.

#20 Ghost Shadow

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Posted 07 January 2012 - 10:25 PM

i noticed prices went up for the headlamps since i bought them. I got it from autolamps plus in florida. aftermarket and its been fine for the last 18 months
1998 Olive Green V70 T5 Manual - 155k Awesome stock car http://tinyurl.com/85mh7z3
2003 Nautic Blue XC90 T6 3rd tranny - 162k Modded http://tinyurl.com/74pwukq
2001 Nautic Blue C70 T5 Manual - 92k Not stock at all http://tinyurl.com/75zhepq





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