Vehicle Segment:
Compact Executive Sedan
Key Selling Points:
Safety, comfort, distinctive Scandinavian design, performance options.
Primary Competitors:
BMW 3 Series, Audi A4, Mercedes-Benz C-Class, Acura TL, Lexus IS.
Manual Value Proposition:
Provides comprehensive, step-by-step guidance for DIY enthusiasts and professional mechanics to maintain and repair the Volvo S60 across multiple model years, ensuring accurate and efficient service.
Digital Delivery Advantage:
Instant download provides immediate access to crucial repair information, eliminating shipping costs and delays.
Covered Years:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Type:
Workshop Service Manual / Repair Manual
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, engine management (ECU), turbocharging (if applicable)
Transmission Systems:
Manual transmission, automatic transmission, clutch, drivetrain, AWD systems
Chassis Systems:
Suspension (front and rear), steering, brakes (hydraulic, ABS, EBD), wheels and tires
Electrical Systems:
12V electrical system, battery, charging system, starting system, lighting, instrument cluster, body control modules, infotainment, safety systems (SRS)
Body And Interior:
Body panels, doors, windows, seats, climate control (HVAC), interior trim, safety restraints
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation, testing procedures for various systems
Maintenance Procedures:
Scheduled maintenance, oil changes, fluid flushes, filter replacements, spark plug replacement, belt replacement
Repair Procedures:
Removal, disassembly, assembly, installation of all major components and systems
Adjustment Procedures:
Alignment checks, brake adjustments, clutch adjustments, electrical component calibration
Depth Of Coverage:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and bodywork repairs.
Diagrams And Illustrations:
Pictorial diagrams, exploded views, detailed illustrations, wiring schematics, and photos are extensively used.
Special Tools:
Identification and usage instructions for specific Volvo special service tools.
Torque Specifications:
Detailed torque values for all critical fasteners and assemblies.
Wear Limits:
Specifications for allowable wear on critical components.
Printability:
Yes, all pages are printable.
Readability:
High, designed for clear reading and easy navigation on Windows, Mac, and Linux OS. Requires Adobe Reader.
Binding Method:
Digital Download (no physical binding)
Digital Paper Emulation:
Simulates professional workshop manual quality with clear typography and high-resolution images.
Engine Family Common:
Volvo 'B52' inline-5 cylinder engine
Engine Variants Covered:
2.0L, 2.3L Turbo (T5), 2.4L, 2.4L Turbo (T5, T5 AWD), 2.5L Turbo (T5, T5 AWD, R)
Horsepower Range:
Approximately 163 hp to 300 hp (depending on engine and tuning)
Torque Range:
Approximately 230 Nm to 400 Nm (depending on engine and tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Standard Transmission Type:
5-speed Manual (M56)
Optional Transmission Type:
5-speed Geartronic automatic transmission (AW55-50SN/AW55-51SN)
AWD Availability:
All-Wheel Drive (AWD) was available, particularly with turbo-charged engines, utilizing a Haldex clutch system.
NHTSA Front Impact Rating:
5-Star (for driver and front passenger in many configurations)
IIHS Top Safety Pick:
The S60 consistently performed well in IIHS crash tests for its era, often earning 'Good' ratings.
Active Safety Systems:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), DSTC (Dynamic Stability and Traction Control), TRACS (Traction Control System).
Passive Safety Features:
Whiplash Protection System (WHIPS), Side Impact Protection System (SIPS), inflatable side curtain airbags (IC), front airbags, seatbelt pretensioners.
Infotainment System:
Premium audio systems (e.g., Dynaudio), optional navigation systems, CD players, and early forms of Bluetooth integration were available depending on trim and year.
Driver Assistance Features:
Cruise control, parking assist sensors (rear), rain-sensing wipers (on some models).
Connectivity Options:
OnStar integration was available in certain markets during this period.
Oil Change Interval:
Typically 7,500 to 10,000 miles (12,000-16,000 km) or 12 months, depending on driving conditions and oil type used (refer to manual for exact specifications).
Timing Belt Replacement:
For most engines, timing belt replacement is recommended every 90,000 to 105,000 miles (145,000-170,000 km) or 7-10 years. Some later models may have timing chains.
Engine Oil Type:
Refer to the manual for specific viscosity grades, such as 0W-30, 5W-30, or 5W-40 synthetic oil, often meeting ACEA A5/B5 specifications.
Coolant Type:
Volvo blue or green coolant concentrate (ethylene glycol based) mixed with distilled water.
Automatic Transmission Fluid:
Specific ATF like JWS 3309 (T-IV) or equivalent is typically required. Manual specifies fluid type and capacity.
Common Wear Items:
Front suspension components (control arm bushings, ball joints), rear shock absorbers, PCV system, various sensors (e.g., O2 sensors, MAF sensor), ignition coils, fuel pump.
Turbocharged Engine Considerations:
Regular checks of turbocharger oil feed lines and intercooler hoses are advisable. Proper oil maintenance is critical for turbo longevity.
Volvo Safety Focus:
Volvo's long-standing reputation for safety is a cornerstone of the S60's design and engineering.
First Generation Launch:
Introduced in 2000 for the 2001 model year, replacing the S70. Based on the P2 platform shared with the Volvo V70 and XC70.
Facelift:
Received a significant facelift for the 2005 model year, with updated styling, interior refinements, and improved technology.
Manufacturing Locations:
Primarily produced in Ghent, Belgium, and Torslanda, Sweden.
Safety Awards:
The S60 was recognized for its strong safety performance by organizations like the IIHS and NHTSA throughout its production run.
Consumer Reports Ratings:
Consumer Reports typically provided mixed reviews, often praising its safety and comfort while noting average predicted reliability for some model years.
Emissions Certifications:
Meets relevant emissions standards for its respective model years and markets.
