2002 Volvo S60 Owners Manual

pg. 140 All Wheel Drive (option)

All Wheel Drive (AWD) - general information Your Volvo can be equipped with permanent All Wheel Drive, which means that power is distributed automatically between the front and rear wheels. Under normal driving conditions, most engine's power is directed to the front wheels. However, if there is any tendency for the front wheels to spin, an electronically controlled coupling distributes power to the wheels that have the best traction.

Tire dimensions Volvo recommends that you always drive on tires of the same brand, size, construction (radial), tread pattern, load-, speed-, traction-, temperature-, and treadwear rating. never drive on mixed tires, except for brief periods when the temporary spare tire is in use.

Always use properly inflated tires of correct dimensions. Tire size and inflation pressures are shown on the tire pressure label located inside the fuel filler door.

Tire Rotation Volvo recommends rotating the tires every 7,500 miles (12,000 km). Tires should be rotated front-to-back/back-to- front only. Tires must maintain the same direction of rotation throughout their lifetime, and should never be rotated from one side of the vehicle to the other.

Temporary Spare The temporary spare tire is for temporary, low-speed, short-distance use only. Replace it with a full-size tire as soon as possible, in accordance with "Tire Rotation" above. Do not drive on the temporary spare at speeds above 50 mph (80
km/h) or for distances greater that

pg. 141 Brake system

BRAKE Brake circuit malfunction If one of the brake circuits were to malfunction, the red warning light would come on, the pedal travel would increase slightly, the pedal would feel softer, and extra pressure would be required for normal braking. If the light comes on while driving or braking, stop immediately and check the brake fluid level in the reservoir.

WARNING!

If the fluid level is below the MIN mark in the reservoir or if a "Brake failure - Service urgent" message is displayed in the text window: DO NOT DRIVE. Have the car towed to a Volvo retailer and have the brake system inspected.

NOTE: When the car is at a standstill and the engine is idling, e. g. at a traffic light and the brake pedal is depressed, the pedal may go down slightly. This is a normal function of the power-assisted brake system.

If the brake power-assist does not function The power assist to the brakes functions only when the engine is running. When the car is moving without the engine running, the brake pedal pressure required to stop the car is increased by 3-4 times and the brake pedal feels stiff.

Water on brake discs and brake pads affects braking Driving in rain and slush or passing through an automatic car wash can cause water to collect on the brake discs and pads. This will cause a delay in braking effect when the pedal is depressed. To avoid such a delay when the brakes are needed, depress the pedal occasionally when driving through rain, slush etc. This will remove the water from the brakes. Check that brake application feels normal. This should also be done after washing or starting in very damp or

cold weather.

Severe strain on the brake system The brakes will be subject to severe strain when driving in mountains or hilly areas or towing. Vehicle speed is usually slower, which means that the cooling of the brakes is less efficient than when driving on level roads. To reduce the strain on the brakes, it is advisable not to use the brakes excessively. Instead, shift into a lower gear and let the engine help with the braking. Do not forget that, if you are towing a trailer, the brakes will be subjected to a greater than normal load.

pg. 142 Brake system

Anti-lock brakes (ABS) If the warning lamp lights up there is a malfunction of the ABS system (the standard braking system will however function) and the vehicle should be driven cautiously to a Volvo retailer for inspection. The Anti-lock Braking System (ABS) helps to improve vehicle control (stopping and steering) during severe braking conditions by limiting brake lockup. When the system "senses" impending lockup, braking pressure is automatically modulated in order to help prevent lockup, which could lead to a skid.

The system performs a self-diagnostic test when the engine is started and when the vehicle first reaches a speed of approximately 12 mph (20 km/h). The brake pedal will pulsate several times and a sound may be audible from the ABS control module. This is normal.

To obtain optimal effect from the ABS system, constant pressure should be kept on the brake pedal, keep constant pressure on the brake pedal. Do not pump the brake pedal.

The switching of the ABS modulator will be audible and the brake pedal will pulsate during braking. Please be aware that ABS does not increase the absolute braking potential of the vehicle. While control will be enhanced, ABS will not shorten stopping distances on slippery surfaces.

ABS with EBD (Electronic Brake Force Distribution) EBD is an integrated part of the ABS system. EBD regulates the hydraulic pressure to the rear brakes to help provide optimal braking capacity.

If the BRAKE and ABS warning lights come on at the same time, this could indicate a fault in the brake system.

Stop the car in a suitable place and switch off the engine. Restart the engine. If both warning lights go off, no further action is required. If both lights are still on after the engine has been restarted, switch off the engine again and check the brake fluid

level (see page 172 for the location of the brake fluid reservoir).

If the brake fluid level is above the MIN mark, drive carefully to an authorized Volvo retailer and have the brake

system inspected.

WARNING!

If the fluid level is below the MIN mark in the reservoir or if a "Brake failure - Service urgent" message is displayed in the text window: DO NOT DRIVE. Have the car towed to a Volvo retailer and have the brake system inspected.

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2 0 0 2 VOLVO

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Wheels and tires pg. 155 Wheels and tires 156
General information 158
Tire pressure 159
Tread wear indicators Changing wheels 160
Uniform Tire Quality Grading 162

pg. 156 General information

General information about wheels and tires Your vehicle is equipped with tires according to the tire information label on the inside of the fuel filler door.

All tires have a dimension designation.

Example of designation: 215/55R16. 215 section width (mm) 55 relationship between section height and width R radial tire 16 wheel rim diameter (")

The tires have good road holding characteristics and offer good handling on dry and wet surfaces. It should be noted however that the tires have been developed to give these features on snow/ice-free surfaces.

Certain models are equipped with "all-season" tires, which provide a somewhat higher degree of road holding on slippery surfaces than tires without the "all-season" rating. However, for optimum road holding on icy or snow-covered roads - we recommend suitable winter tires on all four wheels. When replacing tires, be sure that the new tires are the same size designation, type (radial) and preferably from the same manufacturer, on all four wheels. Otherwise there is a risk of altering the car's roadholding and handling characteristics.

NOTE: When storing wheel/tire assemblies (e. g. winter tires and wheels), either stand the assemblies upright, or suspend them off the ground. Laying wheel/tire assemblies on their sides for prolonged periods can cause wheel and/or tire damage.

New tires Remember that tires are perishable goods. This tire was manufactured week 15 in 1998! (158). As of 2000,

manufacturing year and week will be indicated with 4 digits (e. g. 0015 means that the tire is manufactured year 2000, week 15).

Improving tire economy:

Maintain correct tire pressure. See the tire pressure label on the inside of the fuel filler door. Drive smoothly: avoid fast starts, hard braking and tire screeching. Tire wear increases with speed. Correct front wheel alignment is very important. Unbalanced wheels impair tire economy and driving comfort. If tires are rotated, they must be kept on the same side of the car so that they revolve in the same direction as before

rotation.

Hitting curbs or potholes can damage the tires and/or wheels permanently.

Flat spots All tires become warm during use. After cooling, when the vehicle is parked, the tires have a tendency to distort slightly, forming flat spots. These flat spots can cause vibrations similar to the vibrations caused by unbalanced wheels. They do, however, disappear when the tire warms up. The degree to which flat spots form depends on the type of cord used in the tire. In cold weather, it takes longer for the tire to warm up and consequently longer for the flat spot to disappear.

CAUTION: The car must not be driven with wheels of different dimensions or with a spare tire other than the one that came with the car. The use of different size wheels can seriously damage your car's transmission.

pg. 157 General information

Snow chains Snow chains can be used on your Volvo with the following restrictions:

Snow chains should be installed on front wheels only. Use only Volvo approved snow chains. Special snow chains must be mounted on 195/65 R15. For tires of other dimensions, consult your Volvo retailer. If accessory, aftermarket or "custom" tires and wheels are installed and are of a size different than the original tires and wheels, chains in some cases CANNOT be used. Sufficient clearances between chains and brakes, suspension and body components must be maintained.

Some strap-on type chains will interfere with brake components and therefore CANNOT be used.

NOTE: Consult your Volvo retailer for additional snow chain information

CAUTION: Check local regulations regarding the use of snow chains before installing

Always follow the chain manufacturer's installation instructions carefully. Install chains as tightly as possible and retighten periodically.

Never exceed the chain manufacturer's specified maximum speed limit. (Under no circumstances should you exceed 31
mph (50 km/h)

Avoid bumps, holes or sharp turns when driving with snow chains.

The handling of the vehicle can be adversely affected when driving with chains. Avoid fast or sharp turns as well as locked wheel braking.

Snow tires, studded tires *

Tires for winter use:

Owners who live in or regularly commute through areas with sustained periods of snow or icy driving conditions are strongly advised to fit suitable winter tires to help retain the highest degree of traction.

It is important to install winter tires on all four wheels to help retain traction during cornering, braking, and accelerating. Failure to do so could reduce traction to an unsafe level or adversely affect handling. Do not mix tires of different design as this could also negatively affect overall tire road grip.

Volvo recommends195/65 R15 (205/55R16 on turbo models) winter tires on all four wheels.

Winter tires wear more quickly on dry roads in warm weather. They should be removed when the winter driving season has ended.

Studded tires should be run-in 300-600 miles (500-1000 km) during which the car should be driven as smoothly as possible to give the studs the opportunity to seat properly in the tires. The tires should have the same rotational direction throughout their entire lifetime. In other words, if you wish to rotate the wheels, make sure that the same wheels are always on the same side of the car.

NOTE: Please consult state or provincial regulations restricting the use of studded winter tires before installing such tires.

* Where permitted

pg. 158 Tire pressure

Checking and correcting tire pressure The tire pressure label is located on the inside of the fuel filler door.

Check the tire pressure regularly. The tire pressure should be corrected only when the tires are cold. With warm tires, correct only when the pressure is too low. The tire temperature rises after driving just a few miles.

Vehicle loading The tires on your Volvo will perform to specifications at all normal loads when inflated as recommended on the tire information label located on the inside of the fuel filler door. This label lists both tire and vehicle design limits. Do not load your car beyond the load limits indicated.

WARNING!

Improperly inflated tires will reduce tire life, adversely affect vehicle handling and can possibly lead to failure

resulting in loss of vehicle control without prior warning.

Temporary Spare (certain models) The spare tire in your car is called a "Temporary Spare". It has the following designation: T125/80 R17.

Recommended tire pressure (see decal on Fuel filler door) should be maintained irrespective of which position on the car the Temporary Spare tire is used on. In the event of damage to this tire, a new one can be purchased from your Volvo retailer.

WARNING!

Current legislation prohibits the use of the "Temporary Spare" tire other than as a temporary replacement for a punctured tire. It must be replaced as soon as possible by a standard tire. Road holding and handling may be affected with the "Temporary Spare" in use. Do not exceed 50 mph (80 km/h). Do not drive farther than 50 miles (80 km) on a temporary spare tire.

CAUTION: The car must not be driven with wheels of different dimensions or with a spare tire other than the one that came with the car. The use of different size wheels can seriously damage your car's transmission.

NOTE: Certain models may be equipped with a full-size spare tire. When used, it should be inflated to the same pressure as the tire it is replacing.

pg. 159 Tread wear indicators

Tires have tread wear indicators The tires have wear indicator strips running across or parallel to the tread.

When approx. 1/16" (1.6 mm) is left on the tread, these strips become visible and indicate that the tire should be replaced.

Tires with less than 1/16" (1.6 mm) tread have a very poor grip in rain or snow.

When replacing worn tires, it is recommended that the tire be identical in type (radial) and size as the one being replaced. Using a tire of the same make (manufacturer) will prevent alteration of the driving characteristics of the vehicle.

pg. 160 Changing wheels

Changing wheels The spare wheel is located under the carpet on the trunk floor. The jack and crank are secured in the wheel recess.

There are two jack attachment points on each side of the car (see illustration on next page). To change a wheel:

Engage the parking brake. Put the gear selector in (P) ark (automatic transmission) or reverse (manual transmission).

Remove the wheel cap (where applicable) using the lug wrench in the tool kit. With the car still on the ground, use the lug wrench to loosen the wheel bolts 1/2 - 1 turn. Turn the bolts

counterclockwise to loosen.

CAUTION: The car must not be driven with wheels of different dimensions or with a spare tire other than the one that came with the car. The use of different size wheels can seriously damage your car's transmission.

Correct tightening torque on wheel bolts must be observed. The wheel bolts should never be greased or lubricated. The extended, chromed wheel bolts must not be used with steel rims, as they make it impossible to fit the hub caps.

pg. 161 Changing wheels

 Position the jack correctly on the bar in the attachment (see illustration above) and crank while simultaneously guiding the base of the jack to the ground. The base of the jack must be flat on a level, firm, non-slippery surface. Before raising the car, check that the jack is still correctly positioned in the attachment.

Raise the vehicle until the wheel to be changed is lifted off the ground. Unscrew the wheel bolts completely and carefully remove the wheel so as not to damage the threads on the studs. NOTE: To avoid excessive wear and the necessity of rebalancing, mark and reinstall wheels in the same location and position as before removal. To lessen the chance of imbalance, each wheel hub is equipped with a guide stud to ensure that a removed wheel can be reinstalled in its original position (as when changing over to winter tires/wheels).

Installing the wheel

Clean the contact surfaces on the wheel and hub. Lift the wheel and place it on the hub. Install the wheel bolts and tighten hand-tight. Using the lug wrench, tighten crosswise until all bolts are snug. Lower the vehicle to the ground and alternately tighten the bolts crosswise to 102 ft. lbs. (140 Nm). Install the wheel cap (where applicable).

WARNING!

The jack must correctly engage the bar in the jack attachment. The car's weight must not rest on the jack attachment. See illustration "Attaching the jack" to the left.

Be sure the jack is on a firm, level, non-slippery surface.

Never allow any part of your body to be extended under a car supported by a jack. Use the jack intended for the car when replacing a wheel. For any other job, use stands to support the side of the car being worked on.

Apply the parking brake and put the gear selector in the (P) ark position (or reverse on manual transmissions).

Block the wheels standing on the ground, use rigid wooden blocks or large stones. The jack should be kept well-

greased.

pg. 162 Uniform Tire Quality Grading

Uniform Tire Quality Grading ALL PASSENGER CAR TIRES MUST CONFORM TO FEDERAL SAFETY REQUIREMENTS IN ADDITION TO THESE GRADES

Quality grades can be found, where applicable, on the tire sidewall between the tread shoulder and maximum section width. For example: Treadwear 200 Traction AA Temperature A

TREADWEAR The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire graded 150 would wear one and one half (1 1/2) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and many depart significantly from the norm due to variation in driving habits, service practices and differences in road characteristics and climate.

TRACTION The traction grades, from highest to lowest, are AA, A, B, and C, as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance..

WARNING!

The traction grade assigned to this tire is based on braking (straight-ahead) traction tests and is not a measure of cornering (turning) traction.

TEMPERATURE The temperature grades are AA (the highest), A, B, and C, representing the tire's resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a minimum level of performance that all passenger car tires must meet under the Federal Motor Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law.

WARNING!

The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive speed, under-inflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure.

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2 0 0 2 VOLVO

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Car care pg. 163 Car care Washing and cleaning the car 164
Paint touch up 166

pg. 164 Washing and cleaning the car

Washing and cleaning the car

The car should be washed at regular intervals since dirt, dust, insects and tar spots adhere to the paint and may cause

damage. It is particularly important to wash the car frequently in the wintertime to prevent corrosion, when salt has been used on the roads.

When washing the car, do not expose it to direct sunlight. Use lukewarm water to soften the dirt before you wash

with a sponge, and plenty of water, to avoid scratching.

Bird droppings: Remove from paintwork as soon as possible. Otherwise the finish may be permanently damaged. A detergent can be used to facilitate the softening of dirt and oil. A water-soluble grease solvent may be used in cases of sticky dirt. However, use a wash place equipped with a

drainage separator.

Dry the car with a clean chamois and remember to clean the drain holes in the doors and rocker panels. Tar spots can be removed with kerosene or tar remover after the car has been washed. A stiff-bristle brush and lukewarm soapy water can be used to clean the wiper blades. Frequent cleaning improves

visibility considerably.

Wash off the dirt from the underside (wheel housings, fenders, etc.). In areas of high industrial fallout, more frequent washing is recommended.

CAUTION: During high pressure washing, the spray mouthpiece must never be closer to the vehicle than 13" (30 cm). Do not spray into the locks.

When washing or steam cleaning the engine, avoid spraying water or steam directly on the electrical components or toward the rear side of the engine.

After cleaning the engine, the spark plug wells should be inspected for water and blown dry if necessary.

Suitable detergents: Special car washing detergents should be used. A suitable mixture is about 2.5 fl. oz. (8.5 cl) of detergent to 2.6 US gal. (10 liters) of warm water. After washing with a detergent the car should be well rinsed with clean water.

Bumpers: Wash the bumpers with the same cleaning agent used on the rest of the car. Never clean the bumpers with gasoline or paint thinner. Difficult spots can be removed with denatured alcohol. To avoid scratches, do not dry the bumpers with paper.

NOTE: When washing the car, remember to remove dirt from the drain holes in the doors and sills.

Automatic car wash An automatic car wash is a simple and quick way of washing the car. Bear in mind, however, that an automatic car wash can never replace a proper handwashing. During the first months of the car's life - while the paint is still curing - we recommend that you handwash the car.

WARNING!

When the car is driven immediately after being washed, apply the brakes several times in order to remove any moisture from the brake linings. Engine cleaning agents should not be used when the engine is warm. This constitutes a fire risk.

Automatic washing - simple and quick

We do NOT recommend washing your car in an automatic wash during the first six months (because the paint will

not have hardened sufficiently).

An automatic wash is a simple and quick way to clean your car, but it is worth remembering that it may not be as

pg. 165 Washing and cleaning the car

thorough as when you yourself go over the car with sponge and water. Keeping the underbody clean is most important, especially in the winter. Some automatic washers do not have facilities for washing the underbody.

Before driving into an automatic car wash, make sure that side view mirrors, auxiliary lamps, etc, are secure, and

that any antenna( s) are retracted or removed. Otherwise there is risk of the machine dislodging them.

Polishing and Waxing

Normally, polishing is not required during the first year after delivery, however, waxing may be beneficial. Before applying polish or wax the car must be washed and dried. Tar spots can be removed with kerosene or tar

remover. Difficult spots may require a fine rubbing compound.

After polishing use liquid or paste wax. Several commercially available products contain both polish and wax. Waxing alone does not substitute for polishing a dull surface. A wide range of polymer-based car waxes can be purchased today. These waxes are easy to use and produce a

long-lasting, high-gloss finish that protects the bodywork against oxidation, road dirt and fading.

Do not polish or wax your car in direct sunlight (the surface of the car should not be warmer than 113° F (45° C).

Cleaning the upholstery

The fabric can be cleaned with soapy water or a detergent. For more difficult spots caused by oil, ice cream, shoe

polish, grease, etc., use a clothing/fabric stain remover.

The plastic in the upholstery can be cleaned with a soft cloth and mild soap solution. Leather upholstery/suede-like upholstery (alcanteraª) can be cleaned with a soft cloth and mild soap solution. For

more difficult spots, Volvo offers a leather care kit.

Under no circumstances should gasoline, naphtha or similar cleaning agents be used on the plastic or the leather

since these can cause damage.

Cleaning the seat belts Clean only with lukewarm water and a mild soap solution.

Cleaning floor mats The floor mats should be vacuumed or brushed clean regularly, especially during winter when they should be taken out for drying. Spots on textile mats can be removed with a mild detergent.

Bear in mind

Take extra care when removing stains such as ink or lipstick since the coloring can spread. Use solvents sparingly. Too much solvent can damage the seat padding. Start from the outside of the stain and work toward the center.

pg. 166 Paint touch up

Paint touch up Paint damage requires immediate attention to avoid rusting. Make it a habit to check the finish regularly - when washing the car for instance. Touch-up if necessary.

Paint repairs require special equipment and skill. Contact your Volvo retailer for any extensive damage.

Minor scratches can be repaired by using Volvo touch-up paint.

NOTE: When ordering touch-up paint from your Volvo retailer, use the paint code indicated on the model plate. The plate is located in the engine compartment.

Color code Make sure you have the right color. The color code number is on the data plate in the engine compartment.

Minor stone chips and scratches Material:

Primer - can Paint - touch-up pen Brush Masking tape If the stone chip has not gone down to the bare metal and an undamaged color coat remains, you can add paint

immediately after removing dirt.

NOTE: When touching up the car, it should be clean and dry. The surface temperature should be above 60° F (15° C).

Minor scratches on the surface If the stone chip has not penetrated down to the metal and an undamaged layer of paint remains, the touch-up paint can be applied as soon as the spot has been cleaned.

Deep scratches 1. Place a strip of masking tape over the damaged surface. Pull the tape off so that any loose flakes of paint adhere to it. 2. Thoroughly mix the primer and apply it with a small brush.

When the primer surface is dry, the paint can be applied using a brush. Mix the paint thoroughly; apply several thin paint coats and let dry after each application.

3. If there is a longer scratch, you may want to protect surrounding paint by masking it off.

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2 0 0 2 VOLVO

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Maintenance and service pg. 167 Maintenance and service 168
Volvo service Working on your car 170
Hood and engine compartment 172
173
Oils and fluids 177
Wiper blades Battery 178
181
Bulbs Fuses 188

pg. 168 Volvo service

Maintenance service Volvo advises you to follow the service program outlined in the Warranty and Service Records Information booklet. This maintenance program contains inspections and services necessary for the proper function of your car. The maintenance services contain several checks which require special instruments and tools and therefore must be performed by a qualified technician. To keep your Volvo in top condition, specify time-tested and proven Genuine Volvo Parts and Accessories.

The Federal Clean Air Act - U. S. The Clean Air Act requires vehicle manufacturers to furnish written instructions to the ultimate purchaser to assure the proper functioning of those components that control emissions. The maintenance instructions listed in this manual represent the minimum maintenance required. These services are not covered by the warranty. You will be required to pay for labor and material used. Refer to your Warranty and Service Records Information booklet for further details.

Maintenance services Your Volvo has passed several major inspections before being delivered to you, according to Volvo specifications. The maintenance services outlined in the Warranty and Service Records Information booklet, many of which will positively affect your vehicle's emissions, should be performed as indicated. It is recommended that receipts for vehicle emission services be retained in the event that questions arise concerning maintenance.

Inspection and service should also be performed anytime a malfunction is observed or suspected.

Page 169 provides more information about maintenance of emission-related components.

Applicable warranties - U.S.

In accordance with U. S. Federal Regulations, the following list of applicable U. S. warranties is provided. For Canadian specification vehicles, see your separate warranty booklet.

New Car Limited Warranty

 Parts and Accessories Limited Warranty Corrosion Protection Limited Warranty Seat Belt and Supplemental Restraint Systems Limited Warranty Emission Design and Defect Warranty Emission Performance Warranty

These are the Federal warranties; other warranties are provided as required by state law. Refer to your separate Warranty and Service Records Information booklet for detailed information concerning each of the warranties.

pg. 169 Maintenance Service

Periodic maintenance helps minimize emissions Periodic maintenance will help keep your vehicle running well. Your Warranty and Service Records Information booklet provides a comprehensive periodic maintenance schedule up to 150,000 miles (240,000 km) of vehicle service. The schedule includes components that affect vehicle emissions. This page describes some of the emission-related components.

Engine air filter The engine air filter cleans particles from air entering the engine. Replace the engine air filter cartridge with a new one every 37,500 miles (60,000 km) under normal driving conditions. Replace the cartridge more often when the vehicle is driven under dirty and dusty conditions. The cartridge cannot be cleaned, and should always be replaced with a new one.

Fuel filter The fuel filter should be replaced at 105,000 miles (168,000 km). The filter is replaced as one complete unit. Replace more frequently if contaminated fuel is introduced into the tank, or if there is reason to suspect that this has occurred.

Fuel filler cap, tank and lines and connections The ability of the fuel system to contain hydrocarbons is dependent upon a leak-free system. Inspect fuel lines every 30,000 miles (48,000 km). Check for proper sealing of the fuel filler cap which contains "O" ring type seals.

NOTE: If the fuel filler cap is not closed tightly or if the engine is running when the car is refueled, the Check Engine light (Malfunction Indicator) may indicate a fault. However, your vehicle's performance will not be affected. Use only Volvo original or approved fuel filler caps.

Timing belt For proper functioning of the vehicle and its emission control systems, the timing belt must be replaced every 105,000
miles (168,000 km). Engine damage will occur if the belt fails. .

PCV system (on turbocharged models) The nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be inspected at 105,000 miles (168,000 km) and thereafter, at 150,000 mile (240,000 km) intervals.

Spark plugs The spark plugs should be replaced every 60,000 miles (96,000 km) under normal driving conditions. City driving or fast highway driving may necessitate replacement sooner.

Under normal driving conditions, spark plugs require no maintenance between replacement intervals. When installing new plugs, be sure to use the right type and to tighten them correctly. When changing the plugs, clean the terminals and rubber seals. Also check that the suppressor connectors are in good condition. Cracked or damaged connectors should be replaced.

pg. 170 Working on your car

Note the following before you begin working on your car: Battery

Ensure that the battery cables are correctly connected and tightened. Never disconnect the battery when the engine is running (e. g. when replacing the battery). Never use a fast charger to charge the battery. The battery cables should be disconnected when recharging. The battery contains acid that is both corrosive and poisonous. It is important that the battery is handled in an

environmentally friendly way. Let your Volvo dealer assist you.

Hoisting the car If a garage jack is used to lift the car, the two jack attachments points should be used. They are specially reinforced to bear the weight of the car. A garage jack can also be placed under the front of the engine support frame. Take care not to damage the splash guard under the engine. Ensure that the jack is positioned so that the car cannot slide off it. Always use axle stands or similar structures.

If a two-post hoist is used to lift the car, the front and rear lift arm pads should be centered under the reinforced lift plates on the inboard edge of the sill rail (see illustration).

WARNING!

The car ignition system has very high voltage!

The voltage in the ignition system is dangerous!

Do not touch spark plugs, ignition cables or the ignition coil when the engine is running or the ignition is switched on!

The ignition should be switched off when:

Conducting engine tests. Replacing parts in the ignition system, such as spark plugs, ignition coil, distributor, ignition cables, etc.

WARNING!

Never try to repair any part of the SRS or SIPS bag systems yourself. Any interference in the system could cause malfunction and serious injury. Any work should only be performed by an authorized Volvo workshop.

pg. 171 Working on your car

Belt check Check the belt regularly to make sure it is in good condition and is clean. A worn or dirty belt can cause poor cooling and low alternator output as well as impair the operation of the power steering and the air conditioning unit.

NOTE: The drive belt is equipped with a self-tensioning mechanism and requires no adjustment between changes.!

WARNING!

The engine must not be running when this check is performed.

Check coolant level The cooling system must be filled with coolant and not leak to operate at maximum efficiency. Check the coolant level regularly. The level should be between the "MAX" and "MIN" marks on the expansion tank. The check should be made with particular thoroughness when the engine is new or when the cooling system has been drained.

Do not remove the filler cap other than for topping up with coolant. Frequent removal may prevent coolant circulation between the engine and the expansion tank during engine warm up and cooling.

Changing coolant Normally, the coolant does not need to be changed. If the system must be drained, consult your Volvo retailer.

NOTE: Do not top off with water only. This reduces the rust-protective and antifreeze qualities of the coolant and has a lower boiling point. It can also cause damage to the cooling system if it should freeze. Top off with Volvo Genuine Coolant/Antifreeze only (a 50/50 mix of water and antifreeze).

CAUTION: The cooling system must always be kept filled to the correct level. If it is not kept filled, there can be high local temperatures in the engine which could result in damage. Different types of antifreeze/coolant may not be mixed.

WARNING!

Never remove the radiator cap while the engine is warm. Wait until the car cools.

pg. 172 Hood and engine compartment

Opening the hood

Pull the lever located under the left side of the dash to release the hood lock. Lift the hood slightly. Press up the release control located under the front edge of the hood (at the center) and lift.

WARNING!

Check that the hood locks properly when closed!

Engine compartment 1. Expansion tank - coolant 2. Power steering fluid reservoir 3. Washer fluid reservoir 4. Dipstick - engine oil 5. Radiator 6. Cooling fan 7. Oil filler cap - engine 8. Clutch/brake fluid reservoir 9. Relay/fuse box 10. Air cleaner 11. Battery (in trunk) 12. Data plate

WARNING!

The cooling fan (6) may start or continue to operate (for up to 6 minutes) after the engine has been switched off.

pg. 173 Oils and fluids

Oil quality Engine oil must meet the minimum ILSAC specification GF-2, including ACEA A1, API SJ, SJ/CF and SJ/ Energy Conserving.

Your Volvo has been certified using ILSAC oil specification GF-2 5W-30. Volvo recommends use of oil with a quality rating equal to or higher that ILSAC GF-2. Equivalent and better oils include ACEA A1, API SJ, SJ/CF and SJ/Energy conserving. Lower quality oils may not offer the same fuel economy, engine performance, or engine protection.

Depending on your driving habits, premium or synthetic oils may provide superior fuel economy and engine protection. Consult your Volvo retailer for recommendations on premium or synthetic oils.

Oil additives must not be used.

NOTE: Synthetic oil is not used when the oil is changed at normal maintenance services. This oil is only used at customer request, at additional charge. Please consult your Volvo retailer.

Operation in hot climates

When temperatures exceed 86° F (30° C) in your area, Volvo recommends, for the protection of your engine, that you use a heavier weight oil, such as SAE 10W/30. See the viscosity chart below.

Oil viscosity (stable ambient temperatures) Operation in temperate climates Incorrect viscosity oil can shorten engine life. Under normal use when temperatures do not exceed 86° F (30° C), SAE 5W/30 will provide good fuel economy and engine protection. See the viscosity chart at right.

Extreme engine operation Synthetic oils meeting SAE 10W/30 and complying with oil quality requirements are recommended for driving in areas of sustained temperature extremes (hot or cold), when towing a trailer over long distances, and for prolonged driving in mountainous areas.

Changing oil and oil filter Oil and oil filter changes should be made at 7,500 mile (12,000 km) intervals.

Volvo does not recommend the use of oil additives.

Synthetic oil is not used when the oil is changed at the normal maintenance service intervals.

The API Service Symbol "donut" is divided into three parts: The top half describes the oil's performance level. The center identifies the oil's viscosity. The bottom half tells whether the oil has demonstrated energy-conserving properties in a standard test in

comparison to a reference oil.

pg. 174 Oils and fluids

Checking the oil level The oil level should be checked every time the car is refueled. This is especially important during the period up to the first service.

CAUTION: Not checking the oil level regularly can result in serious engine damage if the oil level becomes too low.

Park the car on a level surface and wait for at least 5 minutes after the engine has been switched off. Be sure the oil

level is maintained between the upper and lower marks on the dipstick. Low oil level can cause internal damage to the engine and overfilling can result in high oil consumption. The distance between the dipstick marks represents approx. 1.6 US qt (1.5 liter). The oil should preferably be checked when cold, before the engine has been started.

NOTE: The engine must be stopped when checking the oil.

WARNING!

Do not allow oil to spill onto or come into contact with hot exhaust pipe surfaces.

Adding oil (topping up)

Add oil of the same kind as already used. Capacity (including filter): Normally-aspirated 5-cylinder engine - 5.8 US qts (5.5 liters). Turbo 5-cylinder engine -

6.1 US qts (5.8 liters).

The oil filter should be replaced at every oil change.

pg. 175 Oils and fluids

Washer fluid reservoir The washer fluid reservoir is located in the engine compartment and holds approx. 4.7 US qts. (4.5 liters).

During cold weather, the reservoir should be filled with windshield washer solvent containing antifreeze.

Changing coolant Normally, the coolant does not need to be changed. If the system must be drained, consult your Volvo retailer.

NOTE: Do not top off with water only. This reduces the rust-protective and antifreeze qualities of the coolant and has a lower boiling point. It can also cause damage to the cooling system if it should freeze. Top off with Volvo Genuine Coolant/Antifreeze only (a 50/50 mix of water and antifreeze).

CAUTION: The cooling system must always be kept filled to the correct level. If it is not kept filled, there can be high local temperatures in the engine which could result in damage. Different types of antifreeze/coolant may not be mixed. Check coolant regularly!

WARNING!

Never remove the radiator cap while the engine is warm. Wait until the car cools.

If it is necessary to top up the coolant when the engine is warm, unscrew the expansion tank cap slowly so that the over pressure dissipates.

pg. 176 Oils and fluids

Clutch and brake fluid reservoir The clutch and brake fluid should always be above the MIN mark on the side of the reservoir. Check, without removing the cap, that there is sufficient fluid in the reservoir.

Fluid type: DOT 4+ boiling point > 536° F (280° C), P/N 9437433

Replace: Every second year or 30,000 miles (48,000 km). The fluid should be replaced once a year or every 15,000

miles (24,000 km) when driving under extremely hard conditions (mountain driving, etc.)

Always entrust brake fluid changing to an authorized Volvo retailer.

Power steering fluid reservoir The fluid level should always be between the MIN and MAX marks.

Fluid type: ATF

Replace: No fluid change required

Contents | Top of Page

2 0 0 2 VOLVO

S60

Specifications pg. 193 Specifications 194
Label information 195
Dimensions, weights 197
Capacities 198
Lubricants, Cooling system 198
Three way catalytic converter 199
200
Suspension 201
Bulbs Electrical system 202
203
Engine specifications Transmission 204

pg. 194 Label information

1 Vehicle Emission Control Information Your Volvo is designed to meet all applicable emission standards, as evidenced by the certification label on the underside of the hood. For further information regarding these regulations, please consult your Volvo retailer.

2 Vacuum hose routing (underside of hood)

3 Loads and Tire Pressures (on inside of fuel filler door)

4 Model plate Vehicle Identification Number (VIN). Codes for color and upholstery, etc. The plate is located in the engine compartment, on the inside of the left front fender.

5 Vehicle Identification Number (VIN) * The VIN plate is located on the top left surface of the dashboard. The VIN is also stamped on the right hand door pillar.

6 Federal Motor Vehicle Safety Standards (FMVSS) specifications (USA) and Ministry of Transport (CMVSS) standards (Canada) Your Volvo is designed to meet all applicable safety standards, as evidenced by the certification label on the facing side of the driver's door. For further information regarding these regulations, please consult your Volvo retailer.

7 Child safety latch label

*The Vehicle Identification Number (VIN) should always be quoted in all correspondence concerning your vehicle with the retailer and when ordering parts.

pg. 195 Dimensions, weights

Dimensions Length 180 in. (458 cm) Width 71 in. (180 cm) Height 56.2 in. (143 cm) Wheelbase 107 in. (272 cm) Front track 61.5 in. (156 cm) Rear track 61.4 (156 cm) Turning circle, between curbs 35.4- 38.7 ft. (10.8- 11.8 m) Cargo capacity, trunk SAE V1 - 13.9 (394)

Weights Gross vehicle weight *

5 cyl. (manual transmission) USA 4360 lbs Canada 1980 kg

5 cyl. (automatic transmission) USA 4400 lbs Canada 1996 kg

5 cyl. turbo (manual transmission) USA 4430 lbs Canada 2110 kg

5 cyl. turbo (automatic transmission) USA 4470 lbs Canada 2030 kg

5 cyl. turbo (automatic transmission) AWD USA 4540 lbs Canada 2060 kg

Capacity weight 5 cyl./5 cyl. turbo USA 890 lbs Canada 400 kg

5 cyl. turbo AWD USA 860 lbs Canada 390 kg

Permissible axle weights, front *

5 cyl. USA 2330 lbs Canada 1060 kg

5 cyl. turbo USA 2400 lbs Canada 1010 kg

5 cyl. turbo AWD USA 2420 lbs Canada 1100 kg

Permissible axle weights, rear *

5 cyl./5 cyl. turbo USA 2220 lbs Canada 1010 kg

5 cyl. turbo AWD USA 2310 lbs Canada 1050 kg

Curb weight

5 cyl. USA 3220- 3330 lbs Canada 1465- 1510 kg

5 cyl. turbo USA 3370- 3425 lbs Canada 1510- 1555 kg

5 cyl. turbo AWD USA 3500- 3535 lbs Canada 1590- 1605 kg

* Permissible axle weight or gross vehicle weight must never be exceeded.

pg. 196 Dimensions, weights

Max. loads,

Max. roof load 220 lbs 100 kg Max. trailer weight without brakes 1100 lbs (500 kg) with brakes 2" ball 3300 lbs (1500 kg) 1 7/ 8" ball 3300 lbs (1500 kg) Max. tongue weight ** 165 lbs (75 kg)

** See also section "Trailer towing"

WARNING!

When adding accessories, equipment, luggage and other cargo to your vehicle, the total capacity weight must not be exceeded.

pg. 197 Capacities Fuel tank 18.5/ 21.1 US gal. (70/ 80 liters) *

Engine oil B5244S 5.8 US qts. (5.5 liters) B5234T3 6. 1 US qts. (5.8 liters) B5244T3 6. 1 US qts. (5.8 liters)

Transmission oil manual (M 56) 2. 2 US qts. (2.1 liters) automatic (AW 55- 50) 7.9 US qts. (7.5 liters)

Miscellaneous Power steering 0. 9 US qts. (0.9 liters) Windshield washer reservoir 4. 8 US qts. (4.5 liters) Brake and clutch fluid 0. 69 US qts. (0.65 liters) Air conditioning system 2.2 lbs. (1 kg) R 134a

* Turbo models have 21.1 US gal. (80 liter) fuel tanks.

Minimum octane requirement - AKI 87 (RON 91) unleaded fuel (See also page 128)

pg. 198 Lubricants, Cooling system

Lubricants

Engine oil Meeting minimum ILSAC specification GF- 2, including ACEA A1, API SJ, SJ/ CF and SJ/ Energy Conserving.

Volvo does not recommend the use of oil additives.

Transmission Oil grade: Manual: Volvo synthetic transmission oil 97308
Automatic: Volvo transmission oil 1161540- 8 Different types of oil should never be mixed.

Power steering

Grade: ATF

Brake fluid Fluid type: Brake fluid DOT 4+ boiling point > 536°F (280° C), P/N 94374433

Cooling system Type Positive pressure, closed system. Coolant Volvo original coolant/ antifreeze Volume 5 cyl. non- turbo 8.5 US qts. (8.0 liters) 5 cyl. turbo 9.3 US qts (8.8 liters)

The thermostat begins to open at 194°F (90° C).

pg. 199 Three way catalytic converter

Three- way catalytic converter cautions

Keep your engine properly tuned. Certain engine malfunctions, particularly involving the electrical, fuel or

distributor ignition systems, may cause unusually high three- way catalytic converter temperatures. Do not continue to operate your vehicle if you detect engine misfire, noticeable loss of power or other unusual operating conditions, such as engine overheating or backfiring. A properly tuned engine will help avoid malfunctions that could damage the three- way catalytic converter.

Do not park your car over combustible materials, such as grass or leaves, which can come into contact with the hot

exhaust system and cause such materials to ignite under certain wind and weather conditions.

Excessive starter cranking (in excess of one minute), or an intermittently firing or flooded engine can cause three-

way catalytic converter or exhaust system overheating.

Remember that tampering or unauthorized modifications to the engine, the Electronic Control Module, or the vehicle

may be illegal and can cause three- way catalytic converter or exhaust system overheating. This includes: - Altering fuel injection setting or components. - Altering emission system components or location or removing components. - Repeated use of leaded fuel.

NOTE: Unleaded fuel is required for cars with three-way catalytic converters.)

Output Socket 55 W H 7
55 W HB3
55 W H 1
P10 W -

pg. 200 Bulbs Bulbs Low beam High beam Fog lights, front Side indicator lamps Turn signals, parking lights, front 21 W PY 21 W PY Turn signals, rear 5 W BA 15 s Parking lights, rear Brake light 21 W B A 15 s 21 W BA 15 s Back up lights 5 W BA 15 s Fog light/ Parking lights, rear License plate lighting 5 W W 2.1x9.5 d 5 W SV 8.5
Courtesy lighting, front

Trunk lighting Glove compartment lighting Vanity mirror

5 W SV 8.5
2 W BA 9 s 1.2 W SV 5.5

pg. 201 Suspension Wheel dimension Rim diameter (mm) tire side diameter(mm) Toe- in front (degrees) Toe- in rear (degrees) Toe- in front (mm) rim measurement 2. 2± 0. 7
tire side measurement 2.7± 0.9
Toe- in rear (mm) rim measurement 1. 4± 1. 4
tire side measurement 1.8± 1.8

16" 440
540

15" 415
515
0.1°± 0. 1° 0.1°± 0. 1° 0.2°+± 0.2° 0.2+± 0. 2°

2.3± 0.8
2. 8± 0. 9
1.5± 1.5
1. 9± 1. 9

Rear suspension Individual rear wheel suspension with longitudinal support arms, double link arms and track rods.

Front suspension Spring strut suspension with integrated shock absorbers and control arms linked to the support frame. Power-assisted rack and pinion steering. Safety type steering column.

pg. 202 Electrical system

Electrical system 12- volt system with voltage controlled generator. Single wire system in which the chassis and engine block are used as conductors, grounded on the chassis.

Battery Voltage 12 V Cold start capacity (CCA) 600 A Reserve capacity (RC) 115 min

If you must replace your battery, be sure to replace it with a battery of the same cold start capacity and reserve capacity as the original (See the decal on the battery).

Generator max. current 140 A Starter motor, power 1.4 kW

Spark plugs P/ N272313- 8 or equivalent Gap 0.028- 0.032 in. 0.7- 0.8 mm Tightening torque 22 ft. lbs. (30 Nm) Firing order 1- 2- 4- 5- 3

WARNING!

The distributor ignition system operates at very high voltages. Special safety precautions must be followed to prevent injury. Always turn the ignition off when:

áReplacing distributor ignition components e. g. plugs, coil, etc.

áDo not touch any part of the distributor ignition system while the engine is running. This may result in unintended movements and body injury.

pg. 203 Engine specifications

Engine specifications

Output (kW/ rps) (hp/ rpm) Torque (Nm/ rps) (ft. lbs./ rpm) No. of cylinders Bore (mm) Stroke (mm) Cylinder displacement (dm

( l))

Compression ratio

B5244T3
147/ 100
197/ 6000
285/ 30- 83

B5234T3
184/ 87
247/ 5200
330/ 42- 87
243/ 2500- 5200 210/ 1800- 5000
81
90

B5244S 125/ 98
168/ 5900
230/ 75
170/ 4500
83
90
2.44 (148.6 cu. in.) 2.3 (141.5 cu. in.) 2. 44 (148.6 cu. in.) 10.3: 1

83
90

9. 0: 1

8.5: 1

Charge air cooler (Intercooler) Turbocharged engines employ a turbocompressor to force air into the engine inlet manifold and a charge air cooler to cool the compressed inlet air. The resulting increase in air flow raises pressure in the intake manifold and increases engine power over that developed by the normally-aspirated engine. The charge air cooler (which resembles a radiator) is located between the turbo- compressor and inlet manifold.

Fuel system The engine is equipped with a multiport fuel injection system.

pg. 204 Transmission

Gear ratios M56H M56L AW55-50
Gear 1st 3.07: 1 3.39: 1 4.77: 1
2nd 1.77: 1 1.90: 1 3.00: 1
3rd 1.19: 1 1.19: 1 1.96: 1
4th 0.87: 1 0.87: 1 1.32: 1
5th 0.70: 1 0.70: 1 1.02: 1
Reverse 2.99: 1 3.30: 1 3.23: 1
Final drive 4.25: 1 4.00: 1 2.44: 1

pg. 205 Volvo On Call

Volvo On Call Roadside Assistance Your new Volvo comes with a four year ON CALL roadside assistance. Additional information, features, and benefits are described in a separate information package in your glove compartment.

If you have misplaced your package, dial: In the U.S.A.

1-800-638-6586 (1-800-63-VOLVO) In Canada: 1-800263-0475

Technician certification In addition to Volvo factory training, Volvo supports certification by the National Institute for Automotive Excellence (A.S.E.). Certified technicians have demonstrated a high degree of competence in specific areas. Besides passing exams, each technician must also have worked in the field for two or more years before a certificate is issued. These professional technicians are best able to analyze vehicle problems and perform the necessary service procedures to keep you Volvo at peak operating condition.

Contents | Top of Page

2 0 0 2 VOLVO

S60

58 , 61
2 , 31 , 142
111
39
73
13
172
55 , 58 , 62
59
55
18
12
117 , 125
140
157
146
02 , 31
41
46 , 110
63
82
81
73
57
56
133
136
137
137
37
44
140

Index pg. 207 Index A/C (air conditioning) ABS Accessory bracket Adjustable steering wheel Advanced User Mode (AUM) - radio Air bags - dual threshold/stage Air cleaner Air distribution Air quality sensor Air vents Airbag - Side Impact (SIPS) Airbags (front) Alarm All Wheel Drive All Wheel Drive - snow chains All Wheel Drive - towing Anti-lock Brake System (ABS) Approach lighting Ashtray Audio Audio systems - general information Audio systems - specifications AUM AUTO (climate control) Automatic Climate Control, ECC Automatic gearbox Automatic transmission Automatic transmission - adaptive system Automatic transmission - kickdown Auxiliary lamps Average speed AWD

Back up light Backrest Bass Battery Battery - replacing Belt check Blower (fan) Booster cushion Booster cushion (integrated) Brake circuit Brake fluid Brake light Brake system Bulbs Capacities Carbon Monoxide - Important Warning Cargo compartment Cassette player Catalytic converter CD player Ceiling lighting Center console - storage compartments Central locking system - remote control Changing coolant Changing oil and oil filter Changing wheels Check Engine warning light Child restraint anchorages Child safety Child safety locks Child seat (Isofix fasteners) Cigarette lighter Climate control systems -general information Clock Coat hanger Coin compartment Cold weather precautions Coolant Coolant - changing Coolant - checking level of Cooling system Courtesy light Cruise control

185
113
67
170 , 178 , 202
179
171
57, 61
24
25
141
176
185
32 , 141
181 , 200

197
129
113
74
199
76 , 78
187
110
119
171
173
160
33
26
24
124
25
46
54
30
112
110
153
175
171, 175
171
198
107
45

Cup holder Current fuel consumption Defroster Dimension designation (tires) Direction indicator, rear - bulb Direction indicators Dolby Surround Pro Logic Door mirror defroster Door mirrors Driving economically DSTC Dual- threshold airbags ECC Economical driving Electric socket Electrical system Electrically operated windows Engine - starting Engine compartment Engine oil Engine oil, capacity Engine specifications Engine oil - checking Environment Federal Clean Air Act FIX NEXT SERVICE Floor mats Fog lamp Front seat - backrest Front seats Front seats - heated Front seats - manual adjustment Front seats - power Front seats - power(programming the memory) Front suspension Fuel Fuel filler cap Fuel filler door - unlocking Fuel filler door Fuel gauge Fuel tank, capacity

110 , 111
44

57
156
185
41
79
43
37
133
35 , 38
13

56
133
38 , 46
202
47
131
172
173
197
203
174

168
36
108
33 , 185
103
102
43
102
104
106
201
2 , 128
2 , 130
40
2 , 130
30
197

Fuses Gasoline Gear position Geartronic Geartronic - kickdown Geartronic - manual shifting General information Generator Generator warning light Glove compartment Grocery bag holder Handling Hazard warning flashers Head restraint - center, rear Headlight flasher Headlight washer Headlight wiper blades Headlights Heated front seats High beam "flash" High beam bulb High beam indicator High/ low beams - replacing Hoisting the car HomeLink® Universal Transceiver Hood - opening IC Immobilizer (start inhibitor) Indicator and warning symbols Inflatable Curtain Instrument lighting Instrument panel Integrated booster cushion Interior Interior lighting Intermittent wiping Introduction ISOFIX fasteners (child seats) Jack Jump starting

188

128
135
138
139
139
202
33
111
114

134
43
114
41
42
177
40
43 , 58 , 61
41
183
30
181
170
83
172

20
118
30 , 31
20
40
30
25
101
107
42
25

115 , 161
147

K Keylock Keys Kickdown LED illumination Lighting panel Load carriers Locking Locking steering wheel Locks Long distance trips Long loads - carrying Low beam bulb Lubricants Maintenance Schedule Malfunction indicator light Manual climate control with air conditioning Manual transmission Messages in the display Multifilter with air quality sensor Occupant safety Octane rating Odometer Oil pressure Oil quality Oil viscosity Opening the trunk from the inside Opening/ locking the trunk P Park Paint - color code Paintwork damage Parking brake Parking lights Pen holder Polishing Power seat Power steering fluid Power sun roof Prem- Air Programme type PT

2 , 131
118
137

41
40
152
121
132
117
154
114
182
198

168
33
60
135
36
59

28
128
30
33
173
173
122
122

136, 138
166
166
33 , 46
40
111
165
104
176
50
72

PROPOSITION 65 WARNING Radiator Radio Reading lamps Rear fog lights Rear seat Rear suspension Rear window defroster Rearview mirror/ door mirrors Recirculation REDUCE SPEED Refrigerant (A/ C system) Refueling Remote control - central locking system Replacing the battery Reporting safety defects Reverse gear inhibitor Roadholding Roof racks (load carriers) Safety Safety defects - reporting Seat belt Seat belt maintenance Seat belt reminder Seat belts (keeping child seats in place) Service Service key Service reminder SERVICE REQUIRED SERVICE URGENT Shiftlock Side airbags Side marker lamp SIPS airbags Ski hatch Snow chains Snow tires Spare tires Spare wheel Spark plugs Specifications Speedometer

147

172
67
107
40
113
201
43 , 61
49
58 , 62
36
54
128 , 130
119
179
28
135
134
152

28
10
28
49
27
168
118
34
36
36
2 , 131
18
185
18
114
157
157
158
115
202
193
30

40
Spoiler lamps 135
Sport shifter 12
SRS 143
Stability system 118
Start inhibitor (immobilizer) 132
Starter switch and steering wheel lock 131
Starting the car 35, 37, 143
STC 132
Steering 39
Steering wheel adjustment 132
Steering wheel lock 166
Stone chips 36
STOP ENGINE 36
STOP SAFELY ASAP Storage compartments 110
Storage compartments in the passenger compartment 109
157
Studded tires 50
Sun roof (electrically operated) Sun visor 51
Supplemental Restraint System (SRS) 12
Supplemental Restraint System (SRS) - warning light 33
Suspension 201
Switches in the center console 37
Tachometer Temperature (climate control) Temperature gauge Temporary spare tire Text window - messages TIME FOR REGULAR SERVICE Tires Tires - tread wear indicators Tools Towing Towing - cars with All Wheel Drive Towing a trailer Trailer indicator lamp Trailer towing Transmission - automatic Transmission - automatic Transmission - automatic Transmission - automatic Trip computer Trip odometer

148
136
138
135
135
44
30

156
159
115
145
146
148

30
57
30
158
36

Trunk - opening from the inside Trunk - unlocking Turn signals - normal turns Turn signals - lane change position Type designations Uniform Tire Quality Grading Unlocking Unlocking the trunk Use of Additives Valet key Vanity mirror Vehicle Identification Number (VIN) Vehicle loading VIN (Vehicle Identification Number) Volvo and the environment Volvo On Call W - Winter Warning symbol in center of dashboard Warranties Washer fluid reservoir Washing the car Waxing Weight distribution Weights Wheels WHIPS Windshield washer Windshield washer fluid reservoir Windshield wipers Winter tires Winter/ Wet driving mode Wiper blades

122
122
41
41
194

162 , 162
121
122
129

118
108
194
158
194
205

137 , 139
31
168
172 , 175
164
165
133
195
156
22
42
175
42
156
153
177

Contents | Top of Page

2 0 0 2 VOLVO

S60

Back Cover

Back Cover

Accessory Installation - Important Warning

We strongly recommend that Volvo owners install only genuine, Volvo-approved accessories, and that accessory

installations be performed only by the factory-trained technicians at your authorized Volvo retailer.

Genuine Volvo accessories are tested to ensure compatibility with the performance, safety, and emission systems in your car. Additionally, your authorized Volvo retailer knows where accessories may and may not be safely installed in your Volvo. In all cases, please consult your authorized Volvo retailer before installing any accessory in or on your car.

Accessories that have not been approved by Volvo may or may not be specifically tested for compatibility with your

car. Additionally, an inexperienced installer may not be familiar with some of your car's systems.

Any of your car's performance and safety systems could be adversely affected if you install accessories that Volvo

has not tested, or if you allow accessories to be installed by someone unfamiliar with your car.

Damage caused by unapproved or improperly installed accessories may not be covered by your new car warranty.

See your Warranty and Service Records Information booklet for more warranty information. Volvo assumes no responsibility for death, injury, or expenses that may result from the installation of non-genuine accessories.

Driver Distraction

Driver distraction results from driver activities that are not directly related to controlling the car in the driving environment. Your new Volvo is, or can be, equipped with many feature-rich entertainment and communication systems. These include hands-free cellular telephones, navigation systems, and multipurpose audio systems. You may also own other portable electronic devices for your own convenience. When used properly and safely, they enrich the driving experience. Improperly used, any of these could cause a distraction.

For all of these systems, we want to provide the following warning that reflects the strong Volvo concern for your

safety:

parked.

Never use these devices or any feature of your vehicle in a way that distracts you from the task of driving safely.

In addition to this general warning, we offer the following guidance regarding specific newer features that may be

Never use a hand-held cellular telephone while driving. Some jurisdictions prohibit cellular telephone use by a

Distraction can lead to a serious accident.

found in your vehicles:

driver while the vehicle is moving.

If your car is equipped with a navigation system, set and make changes to your travel itinerary only with the vehicle

Never program your audio system while the vehicle is moving. Program radio presets with the vehicle parked, and

use your programmed presets to make radio use quicker and simpler.

Never use portable computers or personal digital assistants while the vehicle is moving.

A driver has a responsibility to do everything possible to ensure his or her own safety and the safety of passengers in

the vehicle and others sharing the roadway. Avoiding distractions is part of that responsibility.

The following should be checked regularly: *

1 Washer fluid reservoir should be filled with water and solvent (wintertime: windshield washer anti-freeze). See page 175.

2 Power steering- When cold, the level must not be above the COLD mark and when hot it must not be above the HOT mark. Top up if the level drops to the ADD mark with ATF fluid. See page 176.

3 Coolant level should be between the expansion tank marks. Mixture: 50% anti-freeze and 50% water. See page 171.

4 Engine oil level should be between the dipstick marks. The distance between the marks represents approx. 1.6 US qts (1.5 liters). See page 174.

5 Brake fluid - check, without removing the cap, that the level is above the MIN mark. Use brake fluid DOT 4+. See page 176.

Fuel octane rating, see page 128.

Tire pressure, see label located on the inside of the fuel tank cover.

* Engine oil should be check each time the car is refueled.

Bulbs Power Socket US no.

Designation/power

Bulb no. Name 10

Direction indicator/parking light PY 21 W Low beam H7 55 W HB3 55 W High beam H1 55W Fog light (option) Fog light BA 5s 21 W BA 15s 5 W Tail/parking light BA 15s 21 W Brake light Side marker light P 10 W PY 21 W Direction indicator Backup light BA 15s 21 W

Contents | Top of Page

2 0 0 2 VOLVO

S60

Introduction

Welcome to the world-wide family of Volvo owners. We trust that you will enjoy many years of safe driving in your Volvo, an automobile designed with your safety and comfort in mind. To help ensure your satisfaction with this vehicle, we encourage you to familiarize yourself with the equipment descriptions, operating instructions and maintenance requirements/recommendations in this manual. We also urge you and your passengers to wear seat belts at all times in this (or any other) automobile. And, of course, please do not operate a vehicle if you may be affected by alcohol, medication or any impairment that could hinder your ability to drive.

Your Volvo is designed to meet all applicable safety and emission standards, as evidenced by the certification labels attached to the driver's door opening and on the left wheel housing in the engine compartment.

For further information please contact your retailer, or:

In the USA: Volvo Cars of North America Customer Relations P.O. Box 914 Rockleigh, New Jersey 07647-0914 800-458-1552

In Canada: Volvo Canada Ltd. 175 Gordon Baker Road Willowdale, Ontario M2H 2N7 800-663-8255

General Information

Shiftlock (automatic transmission) When your car is parked, the gear selector is locked in the (P) ark position. To release the selector from this position, turn the ignition key to position II (or start the engine), depress the brake pedal, press the button on the front side of the gear selector and move the selector from (P) ark.

Keylock (automatic transmission) When you switch off the ignition, the gear selector must be in the (P) ark position before the key can be removed from the ignition switch. Anti-lock Brake System (ABS) The ABS system in your car performs a self- diagnostic test when the vehicle first reaches the speed of approximately 12 mph (20 km/h). The brake pedal will pulsate several times and a sound may be audible from the ABS control module. This is normal. Fuel filler door The fuel filler door, located on the right rear fender, is connected to your car's central locking system. The driver's door must be unlocked before the fuel filler door can be opened. When you lock your car using the central locking button on the driver's door or remote control, the fuel filler door also locks after a 10-minute delay. If you lock your car with the fuel filler door open, you will need to unlock the car to allow the fuel filler door to be closed again. Fuel filler cap After refueling, close the fuel filler cap by turning it clockwise until it clicks into place. If this cap is not closed tightly or if the engine is running when the car is refueled, the Malfunction Indicator Lamp (" Check Engine" light) will illuminate. Important information Before you operate your car for the first time, please familiarize yourself with the new- engine oil consumption information on page 128. You should also be familiar with the information in chapters one, two and four of this manual. Information contained in the balance of the manual is extremely useful and should be read after operating the vehicle for the first time. The manual is structured so that it can be used for reference. For this reason, it should be kept in the car for ready access. Do not export your Volvo to another country before investigating that country's applicable safety and exhaust emission requirements. In some cases it may be difficult or impossible to comply with these requirements. Modifications to the emission control system( s) may render your Volvo not certifiable for legal operation in the U. S., Canada and other countries. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. Please note that some vehicles may be equipped differently, depending on special legal requirements. Optional equipment described in this manual may not be available in all markets. Volvo reserves the right to make model changes at any time, or to change specifications or design without notice and without incurring obligation. Volvo and the environment

Volvo is committed to the well being of its customers. As a natural part of this commitment, we care about the environment in which we all live. Caring for the environment means an everyday involvement in reducing our environmental impact. Volvo's environmental activities are based on a holistic view, which means we consider the overall environmental impact of a product throughout its complete life cycle. In this context, design, production, product use, and recycling are all important considerations. In production, Volvo has partly or completely phased out several chemicals including freons, lead chromates, naphtanates, asbestos, mercury and cadmium; and reduced the amount of chemicals used in our plants 50% since 1991. Volvo was the first in the world to introduce into production a three-way catalytic converter with a Lambda sond, now called oxygen sensor, in 1976. The current version of this highly efficient system reduces emissions of harmful substances (CO, HC, NOx) from the exhaust pipe by approximately 95% and the search to eliminate the remaining emissions continues. Volvo is the only automobile manufacturer to offer CFC-free retrofit kits for the air conditioning system of all models as far back as the 1975 model 240. Advanced electronic engine controls, refined purification systems and cleaner fuels are bringing us closer to our goal. After Volvo cars and parts have fulfilled their use, recycling is the next critical step in completing the life cycle. The metal content is about 75% of the total weight of a car, which makes the car among the most recycled industrial products. In order to have efficient and well controlled recycling, many Volvo variants have printed dismantling manuals, indicating the weight and material of individual components.

For Volvo, all homogeneous plastic parts weighing more than 1.7 oz. (50 grams) are marked with international symbols that indicate how the component is to be sorted for recycling. In addition to continuous environmental refinement of conventional gasoline-powered internal combustion engines, Volvo is actively looking at advanced technology alternative-fuel vehicles. When you drive a Volvo, you become our partner in the work to lessen the car's impact on the environment. To reduce your vehicle's environmental impact, you can:

Maintain proper air pressure in your tires. Tests have shown decreased fuel economy with improperly inflated tires. Follow the recommended maintenance schedule. Drive at a constant speed. See an authorized Volvo retailer as soon as possible for inspection if the check engine (malfunction indicator) lamp

illuminates, or stays on after the vehicle has started.

Properly dispose of any vehicle-related waste such as used motor oil, used batteries, brake pads, etc. When cleaning your car, use Volvo's own car care products, all of which have systematically been adapted to the

environment. For additional information regarding the environmental activities in which Volvo Cars of North America, Inc. and Volvo Car Corporation are involved, visit our Internet Home Page at: http://www.volvocars.com Prem-Air On the surface of the radiator in the engine compartment, there is a special coating called Prem-Air. Prem-Air works as a catalytic converter, converting most of the ground level ozone passing through the radiator into oxygen, thereby reducing harmful ground-level ozone.

Instruments, switches and controls

1. Front fog lights 2. Headlights/ Parking lights 3. Rear fog light 4. Turn signals/ High/ low beams 5. Cruise control

Page 40
40
40
41
45

4
6. Horn 30
7. Instrument panel 67
8. Audio controls 42
9. Windshield wipers 46
10. Parking brake (hand brake) 37
11. Center console switches 53
12. Climate control 63
13. Audio system 46
14. 12 V socket 43
15. Hazard warning flashers 111
16. Glove compartment 55
17. Panel vents 36
18. Text window 30
19. Temperature gauge 30/ 45
20. Odometer/ Trip odometer/Cruise control indicator 30
21. Speedometer 30
22. Turn signal indicators 23. Tachometer 30
24. Ambient temperature/ Clock/Selected gear indicator 30
30
25. Fuel gauge 31
26. Indicator and warning symbols 27. Cup holder (option) 111
55
28. Panel vents 40
29. Instrument lighting 30. Lighting panel 40
107
31. Reading lights 107
32. Interior lighting 33. Sun roof control 50
4, 10
34. Seat belt reminder 49
35. Rearview mirror 36. Lock button, for all doors 121
47
37. Blocking rear seat power windows 47
38. Controls, power windows 39. Controls, sideview mirrors 49

Contents

Contents Safety Instruments and controls Climate control Audio Interior Locks and alarm Starting and driving Wheels and tires Car care Maintenance and service Specifications Index Back Cover

Contents | Top of Page

2 0 0 2 VOLVO

S60

Safety pg. 9 Safety

Seat belts 10
Airbags (Supplemental Restraint System) 12
Side airbags (SIPS airbags) 18
Inflatable Curtain (IC) 20
Inspection of airbags, inflatable curtains and seat belt tensioners 21
22
WHIPS Child safety 24
Occupant safety, Reporting safety defects 28
pg. 10 Seat belts Seat belts

Not wearing a seat belt is like believing "It'll never happen to me!" Volvo, the inventor of the three-point seat belt, urges you and all occupants of your car to wear seat belts and ensure that children are properly restrained, using an infant, car or booster seat determined by age, weight and height. Volvo also believes no child should sit in the front seat of a car.

NOTE: Legislation in your state or province may mandate seat belt usage. Additionally, most states and provinces have already made it mandatory for occupants of a car to use seat belts.

So, urging you to "buckle up" is not just our recommendation - legislation in your state or province may mandate seat belt usage. The few seconds it takes to buckle up may one day allow you to say, "It's a good thing I was wearing my seat belt."

NOTE: A chime will sound several times if the driver has not fastened his/her seat belt.

To buckle a seat belt:

Pull the belt out far enough to insert the latch plate into the receptacle until a distinct click is heard. The seat belt retractor is normally "unlocked" and you can move freely, provided that the shoulder belt is not pulled out too far. The retractor will lock up as follows:

if the belt is pulled out rapidly during braking and acceleration if the vehicle is leaning excessively when driving in turns For the seat belt to provide maximum protection in the event of an accident, it must be worn

correctly. When wearing the seat belt remember:

The belt should not be twisted or turned. The lap belt must be positioned low on the hips (not pressing against the abdomen).

Make sure that the shoulder belt is rolled up into its retractor and that the shoulder and lap belts are taut.

Before exiting the car, check that the seat belt retracts fully after being unbuckled. If necessary, guide the belt back into the retractor slot.

Child seats: Please refer to page 27 for information on securing child seats with the seat belts.

pg. 11 Seat belts

During pregnancy Pregnant women should always wear seat belts. Remember that the belt should always be positioned in such a way as to avoid any possible pressure on the abdomen. The lap portion of the belt should be located low, as shown in the above illustration.

WARNING!

Seat belts:

Never use a seat belt for more than one occupant. Never wear the shoulder portion of the belt under the arm,

behind the back or otherwise out of position. Such use could cause injury in the event of an accident. As seat belts lose much of their strength when exposed to violent stretching, they should be replaced after any collision, even if they appear to be undamaged.

Never repair the belt on your own; have this work done by an authorized Volvo retailer only. Any device used to induce slack into the shoulder belt portion of the three-point belt system will have a

detrimental effect on the amount of protection available to you in the event of a collision.

The seat back should not be tilted too far back. The shoulder belt must be taut in order to function properly. Do not use child safety seats or child booster cushions/backrests in the front passenger's seat. We also recommend

that children who have outgrown these devices sit in the rear seat with the seat belt properly fastened.

pg. 12 Airbags (Supplemental Restraint System)

Driver's side airbag As an enhancement to the three-point seat belt system, your Volvo is equipped with a Supplemental Restraint System (SRS) to complement the three-point seat belt system. The inflatable airbag is installed folded up in the center of the steering wheel. The wheel is embossed with SRS.

WARNING!

Never drive an SRS equipped car with your hands on the steering wheel pad / airbag housing.

Passenger side airbag The airbag on the front passenger side is folded up in a compartment above the glove compartment. The panel is embossed SRS.

WARNING!

No objects, accessory equipment or stickers may be placed on, attached to, or installed near the SRS cover in the center of the steering wheel, the SRS cover above the glove compartment or the area affected by airbag deployment.

WARNING!

As its name implies, SRS is designed to be a SUPPLEMENT to - not a replacement for - the three-point belt system. For maximum protection, wear seat belts at all times. Be aware that no system can prevent all possible injuries that may occur in an accident.