🏷️ Basic Information

Make:

Volvo

Model:

S60

Year:

2005

Generation:

P2 (Second Generation)

👋 Introduction

Market Segment:

Premium Mid-size Sedan

Key Competitors 2005:

BMW 3 Series, Audi A4, Mercedes-Benz C-Class, Acura TL, Lexus ES

Brand Philosophy:

Volvo is renowned for its emphasis on safety, comfort, and Scandinavian design.

Manual Value Proposition:

Provides professional-level repair and maintenance information, enabling significant cost savings for owners.

📋 Manual Details

Model Variants Covered:

All Models/Engines/Trim/Transmission Types

Geographic Coverage:

Global (reflecting factory specifications)

Estimated Page Count:

Likely over 1500 pages (typical for comprehensive workshop manuals)

Type:

Workshop Repair Service Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

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.

📊 Manual Specifications

Format:

PDF

Printable:

Full Printable

Zoom Capability:

YES (Zoom IN/OUT functionality)

Binding:

Digital Download (No physical binding)

Paper Type:

N/A (Digital format)

Delivery Method:

Instant Download

Software Requirements:

Adobe PDF Reader & WinZip

Operating Systems:

Compatible with All Versions of Windows & Mac

⚙️ Engine Specifications

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.

🔧 Transmission

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

📐 Dimensions

Length:

Approx. 4603 mm (181.2 in)

Width:

Approx. 1762 mm (69.4 in)

Height:

Approx. 1428 mm (56.2 in)

Wheelbase:

Approx. 2715 mm (106.9 in)

Curb Weight:

Varies by model/drivetrain, typically 1450 - 1650 kg (3197 - 3638 lbs)

Trunk Volume:

Approx. 473 liters (16.7 cu ft)

🛡️ Safety Features

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.

💡 Technology Features

Audio System Options:

Various Volvo Premium Sound systems, often with CD player and optional subwoofer.

Navigation System:

Optional factory-installed GPS navigation system.

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional rear parking assist sensors.

Telematics:

Optional Volvo On Call telematics system.

Climate Control:

Automatic Climate Control (ECC) with pollen filter.

🔧 Maintenance

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.

Brake Fluid:

DOT 4

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.

📚 Vehicle History

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

🏆 Awards & Recognition

IIHS Top Safety Pick:

The S60 consistently received high safety ratings from organizations like IIHS and NHTSA during its production run.