engine VOLVO S60 2001 Service Manual
[x] Cancel search | Manufacturer: VOLVO, Model Year: 2001, Model line: S60, Model: VOLVO S60 2001Pages: 128, PDF Size: 2.52 MB
Page 104 of 128
Fuel (line) filter
For proper functioning of the vehicle and its emission control systems, the fuel line 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).
PCV system
The orifice nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be
inspected at 60,000 miles (96,000 km) and thereafter, at 30,000 mile (48,000 km) intervals.
Cabin air filter
Replace the cabin air filter with a new one at 15,000 mile (24,000 km) intervals. Volvo recommends replacing the
filter more often if the car is driven under dirty and dusty condi- tions. The filter cannot be cleaned and therefore
should always be replaced with a new one.
pg. 168 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
environ- mentally 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!
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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. 169 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. 170 Hood and engine compartment
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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.
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pg. 171 Oils and fluids
Oil quality
Meeting 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.
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. Volvo does not
recommend the use of oil additives.
Volvo recommends use of oil with a quality rating equal to or higher than 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.
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 at right.
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 perfor - mance 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.
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pg. 172 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. 173 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.
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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
overpressure dissipates.
pg. 174 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+
Replace: Every second year or 30,000 miles (48,000 km). The fluid should be replaced once a year or every 15,000
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2 0 0 1
VOLVO S60
Specifications
pg. 191 Specifications
Label information 192
Dimensions, weights193
Capacities194
Lubricants, Cooling system195
Three way catalytic converter196
Suspension197
Bulbs198
Electrical system199
Engine specifications200
Transmission201
Volvo On Call202
pg. 192 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
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Capacity weight
All models
USA 890 lbs (400 kg)
Canada 400 kg
Permissible axle weights, front *
5 cyl.
USA 2330 lbs (1057 kg)
Canada 1060 kg
5 cyl. turbo
USA 2400 lbs (1089 kg)
Canada 1010 kg
Permissible axle weights, rear *
All models
USA 2220 lbs (1007 kg)
Canada 1010 kg
Curb weight
5 cyl.
USA 3220- 3330 lbs (1461- 1510 kg)
Canada 1470- 1515 kg
5 cyl. turbo
USA 3370- 3470 lbs (1529- 1547 kg)
Canada 1535- 1580 kg
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)
* Permissible axle weight or gross vehicle weight must never be exceeded.
** 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. 194 Capacities
Fuel tank 18.5/ 21.1 US gal. (70/ 80 liters) *
Engine oil
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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 126
)
pg. 195 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+.
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)
pg. 196 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
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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.)
pg. 197 Suspension
Wheel dimension 15"16"
Rim diameter (mm) 415440
tire side diameter(mm) 515540
Toe- in front (degrees) 0.1°± 0. 1°0.1°± 0. 1°
Toe- in rear (degrees) 0.2°+± 0.2°0.2+± 0. 2°
Toe- in front (mm) rim measurement 2. 2± 0. 72.3± 0.8
tire side measurement 2.7± 0.92. 8± 0. 9
Toe- in rear (mm) rim measurement 1. 4± 1. 41.5± 1.5
tire side measurement 1.8± 1.81. 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. 198 Bulbs
Bulbs OutputSocket
Low beam 55 WH 7
High beam 55 WHB3
Fog lights, front 55 WH 1
Parking lights, front W5 W-
Side indicator lamps P10 W-
Turn signals, front 21 WPY
Turn signals, rear 21 WPY
Parking lights, rear 5 WBA 15 s
Brake light 21 W BA 15 s
Back up lights 21 WBA 15 s
Fog light/ Parking lights, rear 5 WBA 15 s
License plate lighting 5 WW 2.1x9.5 d
Courtesy lighting, front 5 WSV 8.5
Trunk lighting 5 WSV 8.5
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