The Volvo S60, produced for the 2003 model year as part of the P2 generation, represents a blend of Volvo's renowned safety engineering and a more dynamic, sporty design. Available with various engine options, including naturally aspirated and turbocharged inline-5 variants, and transmission choices such as manual and Geartronic automatic, the S60 was designed to offer a compelling driving experience without compromising on comfort or security. Its robust construction, advanced safety features like ABS, traction control, and a comprehensive airbag system, along with Volvo's commitment to occupant protection through features like WHIPS, established it as a safe and reliable choice in its segment.
This workshop repair service manual provides comprehensive guidance for all Volvo S60 2003 models, covering every engine and transmission type. It delves into detailed procedures for engine and transmission service, brake systems, electrical systems with detailed wiring diagrams, HVAC, cooling, fuel, and emission systems, as well as suspension, steering, chassis, body, and interior components. The manual includes essential maintenance schedules, extensive troubleshooting guides, diagnostic procedures, and step-by-step repair instructions, making it an indispensable resource for owners, independent repair shops, and DIY enthusiasts seeking to maintain and repair their vehicle effectively.
First Generation Codes:
P2
Target Audience:
Volvo S60 2003 owners, independent repair shops, DIY enthusiasts.
Value Proposition:
Provides professional-level repair and maintenance information, saving significant costs compared to dealership servicing.
Accuracy Completeness:
Described as the same manual used by local service/repair shops, original factory information.
Visual Guidance:
Includes hundreds of diagrams, detailed illustrations, drawings, and photos.
User Friendliness:
Easy-to-follow directions, numbered instructions, and a numbered table of contents.
Covered Models:
All Volvo S60 2003 models/engines/trims/transmission types
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as comprehensive)
Type:
Workshop Repair Service Manual
Engine Service Repair:
Complete engine service and repair procedures.
Transmission Service Repair:
Complete transmission service and repair procedures for all types.
Brake System:
Detailed coverage of the brake system.
Electrical System:
Comprehensive coverage including detailed wiring diagrams.
Suspension Steering:
Coverage for suspension and steering systems.
Cooling Fuel Emission:
Includes cooling system, fuel injection/fuel system, and emission system.
HVAC Engine Control:
Coverage for Heater/Air Conditioning and Engine Control Systems.
Chassis Body Restraint:
Includes chassis/body, and restraint systems.
Interior Drivetrain:
Covers interior components, differential/drive, and axles.
Maintenance:
General maintenance, periodic lubrication, and preventative maintenance procedures.
Troubleshooting:
Extensive troubleshooting guides and procedures.
Diagnostics:
Comprehensive diagnostic information for all systems.
Repair Rebuild:
Detailed step-by-step repair and disassembly/assembly procedures.
Electrical Diagnosis:
Specific procedures for diagnosing and repairing electrical system problems.
Depth:
Professional technician level, covering complex diagnostics and repairs.
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT enabled for detailed viewing
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip (or equivalent unzipping software)
Operating Systems:
Compatible with all versions of Windows & Mac
Engine Variants Covered:
The manual covers All Engines for the 2003 S60. Specific engine options for the 2003 Volvo S60 include the 2.4L Naturally Aspirated Inline-5 (often designated B5244S2) and the 2.5L Turbocharged Inline-5 (often designated B5254T2). Higher performance 'R' models would have a more powerful 2.5L Turbo variant.
Estimated Horsepower Torque Range:
Horsepower typically ranged from 168 hp for naturally aspirated engines to 257 hp for the S60R. Torque figures also varied accordingly.
Fuel Injection Type:
Multi-port Fuel Injection (MPI) or Sequential Electronic Fuel Injection (SEFI) depending on the specific engine variant.
Spark Plug Recommendation:
The manual would specify the correct spark plug type and gap for each engine variant (e.g., for the B5244S2 and B5254T2, platinum or iridium plugs are common).
Oil Type Capacity:
Manual would specify Volvo's recommended oil viscosity (e.g., 5W-30 or 0W-30 synthetic) and oil capacity for each engine (typically around 5-7 quarts).
Standard Transmission Type:
The 2003 S60 was available with both manual and automatic transmissions. For naturally aspirated models, a Getrag 5-speed manual was common. For turbocharged models, a 5-speed Geartronic automatic was also prevalent.
Optional Transmission Type:
For turbocharged models, the 5-speed Geartronic automatic transmission offered manual shifting capability.
Automatic Transmission Features:
The Geartronic automatic transmission typically offered Sport mode and manual shifting via the gear selector.
Automatic Transmission Fluid Type:
The manual would specify the exact Volvo-approved automatic transmission fluid (ATF) type, likely a Dexron III/Mercon equivalent or a specific Volvo proprietary fluid.
Length:
Approximately 182.2 inches
Width:
Approximately 70.3 inches
Height:
Approximately 56.2 inches
Curb Weight Range:
Curb weight typically ranged from approximately 3,200 to 3,600 lbs, depending on engine and transmission.
Wheelbase:
Approximately 109.9 inches
Tire Size Range:
Common tire sizes included 205/55R16, 215/55R16, 225/45R17, and 235/40R18 for performance models.
Bolt Pattern:
Typically 5x108mm
NHTSA Front Side Impact Rating:
The S60 generally performed well in crash tests, with NHTSA ratings often achieving 5 stars for frontal and side impacts for the driver and front passenger.
Anti Lock Braking System:
Standard ABS (Anti-lock Braking System) with EBD (Electronic Brakeforce Distribution).
Traction Stability Control:
Standard STC (Spin Traction Control) and optional DSTC (Dynamic Stability and Traction Control) on many models.
Airbag System:
Standard front airbags, side airbags (integrated into seats), and optional Inflatable Curtain (IC) airbags for head protection.
Body Structure:
Volvo's hallmark safety cage construction with energy-absorbing crumple zones.
Seat Design:
Whiplash Protection System (WHIPS) integrated into the front seats.
Audio System:
The S60 featured various audio system options, including premium systems from Volvo, often with CD players and auxiliary inputs.
Navigation System:
Optional factory-integrated navigation systems were available on some models.
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional rear parking sensors were available.
Bluetooth Integration:
Bluetooth connectivity was not standard on the 2003 model year but could be an aftermarket addition or found on very late production models with specific options.
Oil Change Interval:
Typically every 7,500 to 10,000 miles or 12 months, depending on driving conditions and oil type used (as specified in the manual).
Timing Belt Replacement:
The 5-cylinder engines in the 2003 S60 use a timing belt. The manual would specify replacement intervals, commonly around 100,000 miles or 7-10 years.
Transmission Fluid Service:
Intervals for automatic transmission fluid and filter changes would be specified, often around 50,000-60,000 miles, or as indicated by the car's service reminder system.
Coolant Type:
Volvo recommends a specific long-life coolant, typically a blue or green ethylene glycol-based antifreeze with corrosion inhibitors, mixed at a 50/50 ratio with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid is typically specified.
Common Wear Items:
Common wear items on the P2 platform include front control arm bushings, rear shock absorbers, and ignition coils (especially on turbocharged models).
Turbocharger Issues:
For turbocharged models, regular oil changes and proper cool-down after spirited driving are crucial to prevent turbocharger wear. Issues like turbo oil feed line leaks can occur.
Electronic Module Failures:
Certain electronic modules, such as the CEM (Central Electronic Module) or ABS module, can be prone to failure over time, often due to water ingress or component aging.
Volvo Safety Philosophy:
Volvo has a long-standing reputation for safety innovation, with the S60 continuing this tradition from earlier models like the S80 and V70.
First Generation Introduction:
The first generation Volvo S60 (P2 platform) was introduced for the 2001 model year, with the 2003 model year being part of its initial production run.
Design Philosophy:
The S60 was designed as a sportier, more dynamically styled alternative to the S80 sedan, while maintaining Volvo's core values of safety and comfort.
Manufacturing Locations:
Primarily produced at Volvo's Torslanda plant in Sweden and Ghent, Belgium.
Safety Awards:
While specific awards for the 2003 model year are not detailed in the provided text, Volvo vehicles consistently received high safety accolades from organizations like IIHS and NHTSA throughout this period.
