Generation:
First Generation (P2 platform)
Production Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Market Position:
Premium mid-size sedan known for safety, comfort, and Scandinavian design, competing with models like the BMW 3 Series, Mercedes-Benz C-Class, and Audi A4.
Competitive Analysis:
The Volvo S60 (2001-2009) offered a compelling blend of luxury, advanced safety features, and distinctive styling. This manual provides the necessary technical data to maintain and repair these sophisticated vehicles, ensuring they perform as intended.
Key Features:
Emphasis on safety (SIPS, WHIPS), comfortable ride, strong engines, and stylish Scandinavian interior and exterior design.
Coverage Areas:
All Models, Engines, Trim Levels, and Transmission Types for the specified Volvo S60 years
Manual Type:
Workshop Repair Service Manual
File Format:
PDF Download
Print Quality:
Full Printable
Digital Delivery:
Instant Download
Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
Systems Covered:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle
Procedures Included:
Detailed substeps, notes, cautions, warnings, numbered instructions, disassembly, assembly, cleaning, reinstallation, diagnostic procedures, repair procedures, electrical service procedures
Technical Depth:
Comprehensive, professional-grade technical information for diagnostics, repair, and maintenance, suitable for both DIY enthusiasts and professional technicians
Illustration Quality:
Detailed illustrations, drawings, and photos; enlarged insets for detailed part examination
Navigation Features:
Numbered table of contents for fast information retrieval, bold figure numbers for matching illustrations with instructions
Electrical System Details:
Comprehensive coverage of the vehicle's electrical system, including detailed wiring diagrams, troubleshooting procedures for electrical faults, component testing, and module diagnostics.
Chassis Body Details:
Information on chassis components, body repair, structural integrity, alignment procedures, and body hardware.
Print Quality:
High resolution, suitable for printing individual sections or the entire manual.
Paper Type:
N/A (Digital Download)
Binding Type:
N/A (Digital Download)
Searchability:
Likely text-searchable PDF (dependent on the original source quality).
Manual Completeness:
Complete and intact, covering all aspects of service, maintenance, and troubleshooting as used by local repair shops.
Source Quality:
Original workshop manual quality, identical to what professionals use.
Content Type:
Includes diagrams, step-by-step instructions, technical specifications, troubleshooting guides, and wiring diagrams.
Primary Engines:
2.4L Naturally Aspirated Inline-5, 2.4L Turbocharged Inline-5 (T5), 2.5L Turbocharged Inline-5 (GT/AWD models), 2.3L Turbocharged Inline-5 (2.3T/2.5T models), 2.0L Turbocharged Inline-5 (Europe)
Horsepower Range:
168 hp to 300 hp (depending on engine and trim)
Torque Range:
200 Nm to 400 Nm (depending on engine and trim)
Fuel System Type:
Electronic Fuel Injection (EFI)
Engine Control Module:
Various Bosch Motronic/ME series ECUs
Engine Management System Coverage:
Detailed information on Engine Control Module (ECM) functions, sensor inputs, actuator outputs, diagnostic trouble codes (DTCs), and fuel/ignition timing strategies.
Length:
Approx. 4.64 m (182.7 in)
Width:
Approx. 1.8 m (70.9 in)
Height:
Approx. 1.43 m (56.3 in)
Wheelbase:
Approx. 2.71 m (106.7 in)
Curb Weight:
Approx. 1,500 kg - 1,650 kg (3,300 lbs - 3,640 lbs) depending on configuration
IIHS Ratings:
Consistently received 'Good' ratings in IIHS frontal offset crash tests for its generation.
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS), Dynamic Stability and Traction Control (DSTC) available on later models.
Passive Safety Features:
Whiplash Protection System (WHIPS), Side Impact Protection System (SIPS), multiple airbags (front, side, curtain), reinforced safety cage.
Infotainment System:
Standard audio system with CD player. Higher trims featured premium sound systems (e.g., Dynaudio), optional CD changer, and navigation systems on later models.
Driver Assistance Features:
Cruise control, parking sensors (optional on some trims).
Comfort Features:
Climate control (manual or automatic), heated seats, power-adjustable seats with memory, sunroof.
Connectivity Options:
Basic Bluetooth integration for phone calls was introduced on later models. USB connectivity was not standard during this era.
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or 1 year, whichever comes first, depending on driving conditions and oil type. Refer to manual for specific recommendations.
Timing Belt Interval:
On 5-cylinder engines, timing belt replacement is critical, typically around 70,000-100,000 miles (110,000-160,000 km). Consult manual for exact interval.
Engine Oil Specification:
Volvo recommends synthetic engine oil meeting ACEA A3/B3 or A3/B4 specifications, with viscosity grade typically 0W-30 or 5W-30. Specific recommendation depends on engine and climate. (e.g., Castrol EDGE Professional A5/B5 0W-30)
Coolant Specification:
Volvo specified coolant, typically a silicate-free, ethylene glycol-based antifreeze (e.g., Volvo Coolant VCS - Violet)
Transmission Fluid Specification Auto:
AW-1 (Aisin Warner Type 1) for the AW55-50SN/51SN automatic transmission.
Brake Fluid Specification:
DOT 4
Common Issues:
PCV system clogging, engine mounts degradation, minor oil leaks (especially from valve cover gaskets), ABS sensor failures, automatic transmission issues (especially on earlier AW55-50SN models), suspension component wear (control arms, bushings).
Oil Filter Part Number Example:
Volvo OEM 30750002 (or equivalent like Purolator L25609, Bosch 3323, Mann W6014)
Periodic Lubrication Coverage:
Guidance on all lubrication points, including engine oil, transmission fluid, differential fluid, power steering fluid, and chassis lubrication schedules.
Brand Heritage:
Volvo has a long-standing reputation for safety, durability, and innovative design, with a focus on occupant protection.
Model Evolution:
The S60 was introduced as Volvo's sporty mid-size sedan, sharing its P2 platform with the V70 wagon and XC70 crossover. It replaced the S70 and was designed to appeal to a younger demographic while maintaining Volvo's core values.
Production Locations:
Primarily Ghent, Belgium, and Torslanda, Sweden.
