Segment:
Premium Compact Executive Sedan
Competitors:
BMW 3 Series, Mercedes-Benz C-Class, Audi A4, Lexus IS, Acura TL
Brand Philosophy:
Emphasis on safety, durability, comfort, and understated luxury.
Design Language:
Distinctive Scandinavian design, known for its clean lines and functional elegance.
Benefit To Owner:
Enables DIY repairs and maintenance, leading to significant cost savings and better understanding of vehicle systems.
Applicable Years:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Models Covered:
All Volvo S60 models, including all engine, trim, and transmission variants
Estimated Page Count:
Extensive (specific count not provided, but described as 'Complete' and covering A-Z repair procedures)
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital Format (e.g., PDF)
Mechanical Systems:
Engine (diagnostics, repair, overhaul), Fuel System, Cooling System, Exhaust System, Lubrication System
Drivetrain:
Transmission (automatic and manual), Drivetrain components (axles, driveshafts, differentials), Clutch
Chassis And Suspension:
Suspension systems (front and rear), Steering system, Brakes (hydraulic, ABS, EBD, parking brake), Wheels and Tires
Electrical And Electronics:
Electrical system (wiring diagrams, components), Ignition system, Lighting system, Instrumentation, Audio system, Climate control electronics, Engine control module (ECM), Body control module (BCM), Safety systems electronics (SRS, etc.)
Body And Interior:
Body panels (removal, installation, repair), Doors, Windows, Seats, Interior trim, Safety restraint systems (airbags, seatbelts)
Maintenance:
Routine maintenance (oil changes, filter replacements, fluid checks), Scheduled maintenance intervals, Inspections, Lubrication
Diagnostics And Troubleshooting:
Diagnostic procedures for all systems, Common faults and their causes, Troubleshooting guides, Diagnostic Trouble Codes (DTCs)
Repair And Rebuild:
Step-by-step repair instructions for all major components, Engine rebuild procedures, Transmission overhaul, Brake caliper service, Suspension component replacement
Installation And Adjustment:
Component installation and removal, Calibration and adjustment procedures, Wheel alignment specifications
Depth:
Comprehensive from basic maintenance to advanced diagnostics and full component overhaul, including detailed specifications and procedures.
File Type:
Likely PDF (requires Adobe Reader)
Printability:
Printable (individual pages or entire manual)
Binding For Printed:
N/A (Digital format, but implies potential for professional binding if printed)
Paper Quality For Printed:
N/A (Digital format, but implies standard paper if printed)
Engine Codes:
B5244S, B5244S2, B5244S4, B5244S6, B5244S8, B5254T2, B5254T3, B6294S, B6294T
Displacement Range:
2.4L, 2.5L (Turbocharged), 2.8L (Turbocharged - T6)
Horsepower Range:
140 hp (2.4L NA) to 300 hp (2.8L T6)
Torque Range:
170 lb-ft (2.4L NA) to 310 lb-ft (2.8L T6)
Fuel Delivery:
Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI)
ECU Type:
Bosch Motronic or similar, Vehicle Communication Module (VCM)
Timing Belt Or Chain:
Timing Belt (for 5-cylinder engines, typically 105,000 mile / 10 year replacement interval)
Standard Transmission Type:
5-speed Manual (M56, M58)
Optional Transmission Type:
5-speed Geartronic Automatic (AW55-50SN, AW55-51SN, TF-80SC for later models)
AWD Availability:
All-Wheel Drive (AWD) available with certain engine and transmission combinations (e.g., T6)
Automatic Transmission Fluid:
Volvo recommends JWS 3309 (ATF Dexron III H equivalent) or specific Volvo fluid. Refer to manual for exact type and capacity.
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90. Refer to manual for exact type and capacity.
Length:
Approximately 184.5 inches (4686 mm)
Width:
Approximately 70.0 inches (1778 mm)
Height:
Approximately 57.1 inches (1450 mm)
Wheelbase:
Approximately 109.0 inches (2769 mm)
Curb Weight Range:
Approximately 3300 - 3700 lbs (1500 - 1680 kg), depending on engine and configuration.
Trunk Volume:
Approximately 15.0 cubic feet (425 liters)
Standard Wheel Size:
16-inch or 17-inch alloy wheels
Tire Size Range:
205/55R16, 215/55R16, 225/45R17, 235/45R17
NHTSA Crash Test Front:
5-Star (Driver and Passenger)
NHTSA Crash Test Side:
5-Star (Driver and Passenger)
IIHS Crash Test Front Overlap:
Good
IIHS Crash Test Side Impact:
Good
Stability Control:
Electronic Stability Program (ESP) / Traction Control System (TCS)
Braking Systems:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA)
Airbag System:
Front airbags, Side airbags (SIPS - Side Impact Protection System), Inflatable Curtain (IC) airbags
Body Structure:
High-strength steel safety cage, Whiplash Protection System (WHIPS)
Audio System:
Premium sound systems available (e.g., Dynaudio), CD player, optional satellite radio.
Navigation:
Optional factory navigation system (often DVD-based).
Cruise Control:
Standard Cruise Control, optional Adaptive Cruise Control (ACC) on later models.
Parking Assistance:
Optional rear parking sensors available on some models.
Phone Integration:
Optional Bluetooth hands-free system available on some models.
Climate Control:
Manual or dual-zone automatic climate control, optional heated seats.
Headlights:
Halogen headlights standard, optional Bi-Xenon headlights with headlight washers.
Oil Change Interval:
Typically 7,500 miles (12,000 km) or 12 months, whichever comes first. Refer to manual for specific engine oil type and capacity.
Timing Belt Replacement:
105,000 miles (170,000 km) or 10 years for 5-cylinder engines. Critical to follow this interval to prevent catastrophic engine damage.
Transmission Fluid Change:
Recommended every 30,000 - 60,000 miles (50,000 - 100,000 km) for automatic transmissions, depending on driving conditions. Manual transmissions generally have longer intervals or are sealed.
Engine Oil Specification:
API SL/SM, ACEA A3/B3/B4, SAE 0W-30 or 5W-30 (e.g., Mobil 1 0W-30) is often recommended. Always verify with the specific manual for your engine variant.
Coolant Specification:
Volvo Premium Coolant (G48 or similar ethylene glycol based, with corrosion inhibitors). Typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4. Check manual for specific recommendation.
Common Wear Items:
Front control arm bushings, Sway bar links, Wheel bearings, CV joints, Oxygen sensors, PCV system (crankcase ventilation), Ignitor coils.
Potential Electrical Issues:
CEM module (Central Electronic Module) failures, sunroof drain blockages causing water ingress, blower motor resistor failure.
Transmission Concerns:
Automatic transmissions can experience harsh shifting or slipping if fluid is neglected or if solenoids fail. Software updates can sometimes resolve shifting issues.
Founding Principles:
Volvo, founded in 1927, has a long-standing reputation for safety, quality, and innovative engineering.
S60 Introduction:
The S60 was introduced in 2000 for the 2001 model year, as a sportier, more stylish successor to the S70 and a coupe-like sibling to the V70 wagon.
Facelifts And Updates:
Received a significant facelift for the 2005 model year, featuring revised front and rear styling, updated interior, and powertrain enhancements. Minor updates occurred throughout its production run.
Manufacturing Locations:
Primarily manufactured in Ghent, Belgium, and also in Kalmar, Sweden.
IIHS Top Safety Pick:
Often recognized for safety, achieving 'Good' ratings from IIHS and 5-star ratings from NHTSA in various crash tests.
Car And Driver 10Best:
While not explicitly stated for this manual, the S60 has historically been praised by automotive journalists for its performance and handling, especially in sportier trims.
Compliance:
Meets all relevant safety and emissions standards for its model years in North America and Europe.
