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Volvo S60 2009 Workshop Repair Service Manual

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The 2009 Volvo S60 represents the final iteration of its first generation, a sedan renowned for its commitment to safety, robust engineering, and distinct Scandinavian design. Built on the P3...
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Stichworte: 2009 Car Cars S60 Volvo
Volvo S60 2009 Workshop Repair Service ManualVolvo S60 2009 Workshop Repair Service ManualVolvo S60 2009 Workshop Repair Service ManualVolvo S60 2009 Workshop Repair Service Manual
The 2009 Volvo S60 represents the final iteration of its first generation, a sedan renowned for its commitment to safety, robust engineering, and distinct Scandinavian design. Built on the P3 chassis, this model offers a refined driving experience, typically powered by efficient yet capable turbocharged inline-5 engines or the more potent turbocharged inline-6 found in T6 variants. Known for its comfortable interior, advanced safety features such as WHIPS and an optional Blind Spot Information System, and solid build quality, the S60 was designed for discerning owners who value both performance and security. Its production primarily took place in Belgium and South Africa, reflecting Volvo's global manufacturing standards. This comprehensive workshop repair service manual is designed to provide owners, DIY enthusiasts, and professional technicians with the detailed information necessary for the maintenance and repair of all 2009 Volvo S60 models, engines, and transmissions. It covers a vast array of systems, including in-depth engine and transmission service, brake and steering systems, electrical diagnostics with full wiring diagrams, suspension, cooling, fuel injection, emissions, and HVAC systems. The manual also details procedures for chassis and bodywork, restraint systems, and interior components, offering systematic troubleshooting guides, general maintenance schedules, lubrication specifics, and step-by-step disassembly and assembly instructions, all presented with professional-level clarity.
🏷️ Basic Information
Identification
Make:
Volvo
Model:
S60
Year:
2009
Codes
Chassis Code:
P3
Generation
Generation Designation:
Second Generation (2010-2018 model years were a separate redesign, this manual covers the final years of the first generation)
👋 Introduction
Market Position
Target Audience:
Volvo S60 2009 owners, DIY enthusiasts, independent repair shops, and automotive technicians.
Competitive Analysis
Value Proposition:
Offers significant cost savings on repairs and maintenance by providing professional-level guidance, equivalent to dealership resources.
Key Features
Documentation Source:
Original manufacturer documentation, ensuring accuracy and completeness.
Instructional Style:
Detailed substeps, numbered instructions, and visual aids (illustrations, photos) for ease of understanding.
Benefit Of Digital Format:
Convenience of instant download, no shipping costs, easy to print specific sections, and protection from dirt/oil compared to paper manuals.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models/Engines/Trim/Transmissions Types for the 2009 Volvo S60
Page Count
Estimated Page Count:
Hundreds of Pages (as stated in product description)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service Repair:
Comprehensive engine diagnostics, maintenance, repair, and rebuild procedures.
Transmission Service Repair:
Detailed procedures for automatic and manual transmissions, including diagnostics, fluid changes, and internal repairs.
Brake System:
Service and repair for hydraulic systems, ABS, EBD, brake pads, rotors, calipers, and lines.
Wiring Diagram:
Complete electrical wiring diagrams for all vehicle systems.
Electrical System:
Troubleshooting and repair of all electrical components, including power distribution, lighting, sensors, and modules.
Suspension:
Maintenance and repair of front and rear suspension components, including struts, shocks, control arms, and bushings.
Steering:
Service and repair of the power steering system, including pump, rack, and tie rod ends.
Cooling System:
Maintenance and repair of the radiator, coolant hoses, water pump, thermostat, and cooling fans.
Fuel Injection Fuel System:
Diagnosis and repair of fuel pump, injectors, fuel lines, pressure regulator, and fuel tank.
Emission System:
Service and troubleshooting for emissions control components, including catalytic converter, O2 sensors, and EVAP system.
Heater Air Conditional:
Diagnosis and repair of HVAC system, including blower motor, evaporator, condenser, and refrigerant lines.
Engine Control System:
Detailed information on engine control module (ECM), sensors, actuators, and diagnostic trouble codes (DTCs).
Chassis Body:
Body repair, structural components, frame alignment, and body panel replacement.
Restraint System:
Service and repair of airbags, seatbelt pretensioners, and related control modules.
Interior:
Information on interior trim, upholstery, dashboard components, and interior electronics.
Differential Drive:
Maintenance and repair of front and rear differentials, drive shafts, and CV joints.
Axle:
Service and repair of front and rear axles, including bearings and seals.
Procedures Included
General Maintenance:
Routine checks, fluid changes, filter replacements, and lubrication schedules.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues.
Periodic Lubrication:
Specific lubrication points and recommended lubricants for various components.
Disassembly Assembly:
Step-by-step instructions for component removal, reinstallation, and proper torque specifications.
Cleaning Reinstalling:
Procedures for cleaning components prior to reinstallation to ensure proper function and longevity.
Technical Depth
Depth Of Information:
Professional-level diagnostic, repair, and maintenance information used by dealership technicians.
Diagnostic Capabilities:
Extensive diagnostic procedures, including fault code interpretation and symptom-based troubleshooting.
Repair Complexity:
Covers everything from basic maintenance to complete engine and transmission rebuilds.
Electrical Diagnostics:
Detailed troubleshooting for complex electrical systems, combined with comprehensive wiring diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES (Zoom IN/OUT)
Binding Type
Binding:
Digital Download (No physical binding)
Paper Type
Paper Type:
N/A (Digital Format)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Options Available:
While specific engines aren't listed in the product description, the 2009 S60 was commonly available with 2.5L turbocharged inline-5 engines (e.g., B5254T series) and potentially a 3.0L turbocharged inline-6 (T6 models).
Performance
Typical Horsepower Range:
Typically ranged from approximately 200 hp for the 2.5T to 285 hp for the T6 models, depending on the specific engine and tuning.
Typical Torque Range:
Torque figures varied but were generally in the 235 lb-ft to 295 lb-ft range.
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI) with sequential port injection.
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended for turbocharged engines).
🔧 Transmission
Standard
Standard Transmission Type:
The 2009 S60 was predominantly offered with automatic transmissions, typically a Geartronic (sequential shifting) 6-speed automatic.
Optional
Optional Transmission Type:
While less common, some markets may have offered a 6-speed manual transmission on certain engine variants.
Features
Geartronic Functionality:
Allows for manual selection of gears for enhanced driver control.
📐 Dimensions
Exterior
Length:
Approx. 180.2 inches (457.7 cm)
Width:
Approx. 70.4 inches (178.8 cm)
Height:
Approx. 57.0 inches (144.8 cm)
Wheelbase:
Approx. 109.6 inches (278.4 cm)
Weights
Curb Weight:
Varies by model and engine, typically ranging from 3,400 to 3,700 lbs (approx. 1540 to 1680 kg).
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
The 2009 Volvo S60 generally received high safety ratings from organizations like the NHTSA, often achieving 5-star ratings in frontal and side impact tests.
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control System (TCS), and optional Blind Spot Information System (BLIS).
Passive Features
Passive Safety Features:
Advanced front airbags, side-impact airbags, inflatable curtain airbags, Whiplash Protection System (WHIPS), and reinforced safety cage construction.
💡 Technology Features
Infotainment
Infotainment System:
Features typically include an in-dash audio system with CD player, optional satellite radio, and auxiliary input. Higher trims may have an optional navigation system and premium sound.
Driver Assistance
Driver Assistance Features:
Standard features often include cruise control. Optional features may include parking assist sensors and the aforementioned BLIS.
Connectivity
Connectivity Options:
Auxiliary audio input jack for connecting external media devices. Bluetooth hands-free calling might be an option on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles or 12 months, whichever comes first, using synthetic oil. Consult the manual for specific recommendations based on driving conditions.
Timing Belt Replacement:
For turbocharged inline-5 engines, timing belt replacement is typically recommended around 105,000 miles or 10 years. Inline-6 engines may use a timing chain. Check manual for exact interval.
Fluid Specifications
Engine Oil Specification:
API SM/SN, ACEA A3/B4 or A5/B5. Viscosity commonly 0W-30 or 5W-30 synthetic. Check manual for exact specification.
Transmission Fluid Specification:
For automatic transmissions, typically Volvo's own specified ATF or a Dexron-VI compatible fluid. Refer to the manual for the exact specification and fluid type.
Coolant Specification:
Volvo Blue Coolant (or equivalent G48 ethylene glycol-based coolant).
Known Issues
Common Maintenance Items:
PCV (Positive Crankcase Ventilation) system issues leading to oil leaks or rough running, ignition coil failures, and power steering pump leaks can be noted common areas for this generation.
📚 Vehicle History
Brand Heritage
Volvo Brand Focus:
Volvo has a long-standing reputation for safety, comfort, and Scandinavian design, with a commitment to innovation in automotive engineering.
Model Evolution
S60 First Generation Timeline:
The first generation S60 (2000-2009) was based on the P2 platform, known for its sporty handling and distinct styling. The 2009 model year represents the final iteration of this generation before a significant redesign.
Production
Manufacturing Locations:
Primarily manufactured in Belgium and South Africa.
🏆 Awards & Recognition
Recognitions
Safety Awards:
The Volvo S60 consistently received positive safety accolades from organizations such as the IIHS (Insurance Institute for Highway Safety) and NHTSA during its production run.
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