Volvo S60 2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Volvo Model: S60 Year: 2003 Chassis Code: P2 Market Segment: Compact Executive Sedan 👋 Introduction Market Position Positioning: The Volvo S60 is positioned as a...

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Description

🏷️ Basic Information

Identification

Make:

Volvo

Model:

Year:

Chassis Code:

Market Segment:

Compact Executive Sedan

👋 Introduction

Market Position

Positioning:

The Volvo S60 is positioned as a premium compact executive sedan, emphasizing safety, comfort, and Scandinavian design.

Competitive Analysis

Competitors:

Competes with vehicles like the BMW 3 Series, Mercedes-Benz C-Class, Audi A4, and Acura TL.

Key Features

Selling Points:

Renowned for safety features, robust build quality, comfortable ride, and distinctive styling. The 2003 model year represents a period of refinement for the P2 platform.

📋 Manual Details

Coverage

Manual Type:

Workshop Service Repair Manual

Completeness:

Complete Official Full Factory Service Repair Manual

Styles Covered:

All Styles

Format

File Format:

Language:

English

Print Quality:

Printable without restriction

Delivery Method:

Download

Compatibility:

All PC based Windows operating systems and Mac

Required Software:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine:

Engine Service / Repair, Fuel Injection, Fuel System, Emission System, Engine Control System

Drivetrain:

Transmission Service / Repair, Differential / Drive, Axle

Chassis:

Brake System, Suspension, Steering, Chassis / Body

Electrical:

Wiring Diagram, Electrical System

Comfort And Safety:

Heater/ Air Conditional, Restraint System, Interior

Procedures Included

Maintenance:

General Maintenance, Periodic Lubrication

Diagnostics:

Troubleshooting, Electrical System Diagnostics

Repair:

Step-by-step instructions for complete disassembly and reassembly of components

Technical Depth

Detail Level:

In-depth professional quality, suitable for DIYers and experienced mechanics

Illustrations:

Hundreds of photos and illustrations, detailed drawings, enlarged insets

Guidance Features:

Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers

📊 Manual Specifications

Binding Type

Binding Type:

Digital Download (Printable)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Options 2003:

Typically includes a 2.4L turbocharged inline-5 (T5) and a naturally aspirated 2.4L inline-5. Specific engine codes may vary.

Performance

T5 Performance Approx:

Around 257 horsepower and 310 lb-ft of torque (T5 model).

Naturally Aspirated Performance Approx:

Around 168 horsepower and 170 lb-ft of torque.

Fuel System

Fuel Injection Type:

Electronic Fuel Injection (EFI) with sequential port injection.

Fuel Type:

Unleaded gasoline.

🔧 Transmission

Standard

Standard Transmission Type:

Often a 5-speed manual transmission (M56) on select models.

Optional

Optional Transmission Type:

5-speed Geartronic automatic transmission.

Features

Geartronic Functionality:

Allows manual shifting selection via the gear selector.

📐 Dimensions

Exterior

Wheelbase:

Approximately 109.9 inches (2791 mm).

Length:

Approximately 183.2 inches (4653 mm).

Width:

Approximately 71.0 inches (1803 mm).

Height:

Approximately 56.1 inches (1425 mm).

Weights

Curb Weight Approx:

Varies by trim and powertrain, typically between 3300-3500 lbs (1497-1588 kg).

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating 2003:

Five-star rating for driver and front passenger.

IIHS Top Safety Pick Status 2003:

Likely a 'Good' rating in frontal offset crash tests.

Active Features

Active Safety Systems:

ABS (Anti-lock Braking System), EBD (Electronic Brake Distribution), Traction Control System (TCS), Stability and Traction Control (STC) on some models.

Passive Features

Passive Safety Features:

Advanced Frontal Airbags (AFAS), Side Impact Protection System (SIPS), Whiplash Protection Seating System (WHIPS), Inflatable Curtain (IC) available.

💡 Technology Features

Infotainment

Infotainment System Type:

Premium audio systems available, often with CD player, radio. Dolby Surround Pro Logic II system optional.

Driver Assistance

Driver Assistance Features:

Cruise control, parking assist sensors (rear) available on some models.

Connectivity

Connectivity Features:

Limited by modern standards; typically auxiliary input for external devices might be integrated or added aftermarket.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 miles (12,000 km) or 12 months, whichever comes first, using synthetic oil.

Timing Belt Replacement:

If equipped with a timing belt, refer to the manual for specific interval (often around 100,000 miles or 160,000 km).

Fluid Specifications

Engine Oil Specification:

Refer to the manual for exact viscosity grade (e.g., 0W-30 or 5W-30) and API service classification.

Coolant Type:

Volvo coolant (e.g., blue colored ethylene glycol based antifreeze/coolant).

Transmission Fluid Type Automatic:

Volvo ATF AW-1 or equivalent specified fluid.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Issues Potential:

PCV system issues (clogged), ignition coil failures, ABS module failure, O2 sensor faults, power steering leaks, transmission shift quality issues on higher mileage automatics.

📚 Vehicle History

Brand Heritage

Volvo Safety Focus:

Volvo has a long-standing reputation for pioneering automotive safety innovations.

Model Evolution

S60 P2 Platform:

The 2003 S60 is part of the first generation (P2 platform), introduced in 2000. It represented a significant modernization for Volvo's sedan offerings.

Production

Manufacturing Locations:

Primarily manufactured in Ghent, Belgium, and Torslanda, Sweden.

🏆 Awards & Recognition

Recognitions

Safety Awards General:

Volvo models consistently receive high safety ratings from organizations like IIHS and NHTSA.