Engine Service Repair:
Comprehensive coverage including disassembly, assembly, inspection, and repair of all engine components.
Transmission Service Repair:
Detailed procedures for both automatic and manual transmissions, including fluid service, internal component repair, and diagnosis.
Brake System:
Service and repair for ABS, EBD, front and rear brakes, parking brake, and related components.
Electrical System:
In-depth coverage of all electrical circuits, components, diagnosis, and repair, including integrated with wiring diagrams.
Suspension:
Repair and adjustment of front and rear suspension components, alignment procedures, and related systems.
Steering:
Service and repair for power steering system, steering column, and rack and pinion assembly.
Cooling System:
Maintenance and repair of radiator, fan, water pump, thermostat, and coolant system.
Fuel Injection Fuel System:
Diagnosis and repair of fuel pump, injectors, fuel lines, fuel filter, and pressure regulation.
Emission System:
Service and troubleshooting for catalytic converters, O2 sensors, EGR systems, and emission control components.
Heater Air Conditioning:
Maintenance, diagnosis, and repair of HVAC system, including refrigerant handling and component replacement.
Engine Control System:
Detailed diagnostics and repair procedures for the Engine Control Module (ECM) and associated sensors and actuators.
Chassis Body:
Procedures for chassis components, body panel repair, and structural elements.
Restraint System:
Service and safety information related to airbags, seatbelts, and their control modules.
Interior:
Information related to interior trim, components, and systems.
Differential Drive:
Service and maintenance for front and rear differentials, and driveline components.
Axle:
Repair and maintenance of front and rear axles and CV joints.
Wiring Diagram:
Comprehensive and detailed wiring diagrams integrated with electrical system diagnostics.
General Maintenance:
Regular maintenance tasks, fluid checks, filter replacements, and inspections.
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 procedures for dismantling and reassembling all major vehicle systems and components.
Cleaning Reinstalling:
Guidelines for cleaning and correctly reinstalling components during repair.
Diagnostic Procedures:
Detailed diagnostic trees and strategies for various vehicle systems.
Depth:
Professional Level: Covers detailed diagnostic, repair, and maintenance procedures used by factory-trained technicians.
Illustrations:
Includes detailed illustrations, drawings, and photos for clarity.
Instructions:
Numbered step-by-step instructions for all repair procedures.
Critical Information:
Includes notes, cautions, and warnings to highlight critical information.
Part Identification:
Features enlarged inset diagrams for detailed examination of parts.
Engine Options 2005 S60:
2.5L Turbocharged Inline-5 (B5254T2), 2.5L Turbocharged Inline-5 (B5254T3 - T5 models), 2.4L Naturally Aspirated Inline-5 (B5244S2 - base models), 2.3L Turbocharged Inline-5 (B5234T3 - earlier R models, less common in 2005 facelift).
Typical Horsepower Range:
168 hp (2.4L NA) to 257 hp (T5 AWD R)
Typical Torque Range:
225 lb-ft (2.4L NA) to 295 lb-ft (T5 AWD R)
Fuel Delivery:
Sequential Multi-Point Fuel Injection (MPI) with Turbocharging on relevant models.
Engine Management:
Volvo Engine Control Module (VECM) with diagnostic capabilities.
Standard Transmission:
5-speed Manual Gearbox (M56H), 5-speed Geartronic Automatic Transmission (AW55-50SN)
Optional Transmission:
6-speed Manual Gearbox (for performance models), 5-speed Geartronic Automatic Transmission (AW55-50SN - often standard on AWD/T5 models)
Geartronic Functionality:
Allows manual selection of gears for enhanced driver control.
Automatic Transmission Fluid:
Volvo recommends JWS 3309 (e.g., Mobil ATF 3309, Castrol Transmax J)
Manual Transmission Fluid:
API GL-4 or GL-5, viscosity SAE 75W-90
NHTSA Front Impact Driver:
5 Stars (2005 Model)
NHTSA Front Impact Passenger:
5 Stars (2005 Model)
IIHS Front Offset Crash Test:
Good (Top Safety Pick designation)
Anti Lock Braking System:
Standard ABS with EBD (Electronic Brakeforce Distribution)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability Control:
Optional Electronic Stability Control (ESC), sometimes branded as DSTC (Dynamic Stability Traction Control)
Airbag System:
Front airbags, side airbags, and inflatable curtain (IC) airbags.
Seatbelt Pretensioners:
Standard front seatbelt pretensioners.
Whiplash Protection:
Volvo's Whiplash Protection System (WHIPS) in front seats.
Oil Change Interval:
Typically 7,500 to 10,000 miles (12,000 - 16,000 km) or 12 months, whichever comes first, depending on driving conditions.
Timing Belt Replacement:
For naturally aspirated 5-cylinder engines, replace timing belt every 105,000 miles (170,000 km) or 7 years. Turbocharged models may have different intervals; consult manual.
Cabin Air Filter:
Recommended replacement every 15,000 to 20,000 miles (24,000 - 32,000 km).
Engine Oil:
API SM or SN, ILSAC GF-4 or GF-5, SAE 0W-30 or 5W-30 (check specific engine requirements).
Coolant:
Volvo VCS (Volvo Coolant System) or equivalent G48 ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Pcv System Clogging:
Clogged Positive Crankcase Ventilation (PCV) system can lead to oil leaks and internal engine pressure issues.
Egr Valve Issues:
Exhaust Gas Recirculation (EGR) valve can become clogged or fail, leading to rough idling and reduced performance.
Suspension Component Wear:
Front control arm bushings and sway bar links are common wear items.
ABS Module Failure:
ABS control modules can fail, leading to ABS warning lights and loss of ABS functionality.
Volvo Safety Focus:
Volvo has a long-standing reputation for pioneering automotive safety innovations, dating back to the introduction of the three-point seatbelt.
P2 Platform Introduction:
The S60 is based on Volvo's P2 platform, shared with models like the V70, XC70, and XC90.
Facelift 2005:
The 2005 model year saw a significant facelift for the S60, incorporating updated styling cues, revised interior, and new technology features.
Manufacturing Location:
Ghent, Belgium; Kalmar, Sweden
