check engine VOLVO S60 2004 User Guide

fuel economy. If you are not sure whether the gasoline contains deposit control additives, check with the service
station operator.
NOTE: Volvo does not recommend the use of external fuel injector cleaning systems.
Unleaded fuel
Each Volvo has a three-way catalytic converter and must use only unleaded gasoline. U.S. and Canadian regulations
require that pumps delivering unleaded gasoline be labelled "UNLEADED". Only these pumps have nozzles which fit
your car's filler inlet. It is unlawful to dispense leaded fuel into a vehicle labeled "unleaded gasoline only". Leaded
gasoline damages the three-way catalytic converter and the heated oxygen sensor system. Repeated use of leaded
gasoline will lessen the effectiveness of the emission control system and could result in loss of emission warranty
coverage. State and local vehicle inspection programs will make detection of misfueling easier, possibly resulting in
emission test failure for misfueled vehicles.
NOTE: Some U.S. and Canadian gasolines contain an octane enhancing additive called methyl-cyclopentadienyl
manganese tricarbonyl (MMT). If such fuels are used, your Emission Control System performance may be affected,
and the Check Engine Light (malfunction indicator lamp) located on your instrument panel may light. If this occurs,
please return your vehicle to an authorized Volvo retailer for service.
Gasoline containing alcohol and ethers
"Oxygenated fuels"
Some fuel suppliers sell gasoline containing "oxygenates" which are usually alcohols or ethers. In some areas, state or
local laws require that the service pump be marked indicating use of alcohols or ethers. However, there are areas in
which the pumps are unmarked. If you are not sure whether there is alcohol or ethers in the gasoline you buy, check
with the service station operator. To meet seasonal air quality standards, some areas require the use of "oxygenated"
fuel.
Volvo allows the use of the following "oxygenated" fuels; however, the octane ratings listed on this page must still be
met.
Alcohol - Ethanol: Fuels containing up to 10% ethanol by volume may be used. Ethanol may also be referred to as
Ethyl alcohol, or "Gasohol".
Ethers - MTBE: Fuels containing up to 15% MTBE may be used.
pg. 79 Starting and driving
Carbon Monoxide - Important Warning
Carbon monoxide is a poisonous, colorless, and odorless gas. It is present in all exhaust gases. If you ever smell
exhaust fumes inside the vehicle, make sure the passenger compartment is ventilated, and immediately return the
vehicle to your retailer for correction.
Fuel Formulations
Do not use gasoline that contains lead as a knock inhibitor, and do not use lead additives. Besides damaging the
exhaust emission control systems on your car, lead has been strongly linked to certain forms of cancer.
Many fuels contain benzene as a solvent. Unburned benzene has been strongly linked to certain forms of cancer. If you
live in an area where you must fill your own gas tank, take precautions. These may include:
standing upwind away from the filler nozzle while refueling
refueling only at gas stations with vapor recovery systems that fully seal the mouth of the filler neck during refueling
wear neoprene gloves while handling a fuel filler nozzle.
Use of Additives
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After refueling, close the fuel filler cap by turning it clockwise until it clicks into place*.
Allow for fuel expansion by not overfilling the tank. Overfilling could also cause damage to the emission control
systems. Avoid spilling gasoline during refueling. In addition to causing damage to the environment, gasolines
containing alcohol can cause damage to painted surfaces, which may not be covered under the New Vehicle Limited
Warranty.
Do not use gasolines containing methanol (methyl alcohol, wood alcohol). This practice can result in vehicle
performance deterioration and can damage critical parts in the fuel system. Such damage may not be covered under the
New Vehicle Limited Warranty.
* 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 lamp) may indicate a fault. However, your vehicle's performance will not be affected. Use only
Volvo original or approved fuel filler caps.
pg. 81 Starting and driving
Starting the car
Starting the engine
1. Fasten the seat belt.
WARNING!
Before starting, check that the seat, steering wheel and mirrors are adjusted properly. Make sure the brake pedal can
be depressed completely. Adjust the seat if necessary. See pages 54, 56.
2. Apply the parking brake (hand brake) if not already set. The gear selector (automatic transmission) is locked in the
(P )ark position ( SHIFTLOCK ).
Manual transmission: the clutch must be fully depressed.
3. Without touching the accelerator pedal, turn the ignition key* to the starting position. Allow the starter to operate for
up to 10 seconds. Release the key as soon as the engine starts. If the engine fails to start, repeat this step.
NOTE: On certain models, when the car is started, idle speed may be noticeably higher than normal for a short period,
depending on the temperature of the engine. This has been done to help bring components in the emission control
system to their normal operating temperature as quickly as possible, which enables them to function normally.
For cold starts at altitudes above 6000 ft (1800 meters), depress the accelerator pedal halfway and turn the key to the
starting position. Release the pedal slowly when the engine starts.
4. To release the gear selector from the ( P)ark position, the engine must be running (or the ignition key must be in
position II) and the brake pedal must be depressed.
5. Select the desired gear. The gear engages after a very slight delay which is especially noticeable when selecting R.
NOTE: Your car is equipped with a KEYLOCK system (automatic transmission). When the engine is switched off,
the gear selector must be in the ( P)ark position before the key can be removed from the ignition switch.
When starting in cold weather, the transmission may shift up at slightly higher engine speeds than normal until the
automatic transmission fluid reaches normal operating temperature.
CAUTION:
Automatic transmission
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Steering wheel lock
The steering wheel lock might be under tension when the car is parked.
Turn the steering wheel slightly to free the ignition key.
In order to help reduce car theft, make sure the steering wheel lock is engaged before leaving the car.
WARNING!
Never switch off the ignition (turn the ignition key to position 0) or remove the key from the ignition switch while
the car is in motion. This could cause the steering wheel to lock, which would make the car impossible to steer
* The gear selector must be in the ( P)ark position (automatic transmission).
** Please be aware that leaving the key in this position will increase battery drain.
pg. 83 Starting and driving
General information
Economical driving conserves natural resources
Better driving economy may be obtained by thinking ahead, avoiding rapid starts and stops and adjusting the speed of
your vehicle to immediate traffic conditions. Observe the following rules:
Bring the engine to normal operating temperature as soon as possible by driving with a light foot on the accelerator
pedal for the first few minutes of operation. A cold engine uses more fuel and is subject to increased wear.
Whenever possible, avoid using the car for driving short distances. This does not allow the engine to reach normal
operating temperature.
Drive carefully and avoid rapid acceleration and hard braking.
Do not exceed posted speed limits.
Avoid carrying unnecessary items (extra load) in the car.
Maintain correct tire pressure. Check tire pressure regularly (when tires are cold).
Remove snow tires when threat of snow or ice has ended.
Note that roof racks, ski racks, etc, increase air resistance and also fuel consumption.
Avoid using automatic transmission kickdown feature unless necessary.
However, at higher driving speeds, fuel consumption will be lower with the air conditioning on and the windows
closed than with the air conditioning off and the windows open.
Using the onboard trip computer's fuel consumption modes can help you learn how to drive more economically.
Other factors that decrease gas mileage are:
Dirty air cleaner
Dirty engine oil and clogged oil filter
Dragging brakes
Incorrect front end alignment Some of the above mentioned items and others are checked at the standard
Maintenance Service intervals.
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NOTE: Vehicles equipped with automatic transmissions should use (D)rive as often as possible and avoid using
"kickdown" to help improve fuel economy.
WARNING!
Driving with the trunk open: Driving with the trunk open could lead to poisonous exhaust gases entering the
passenger compartment.
If the trunk must be kept open for any reason, proceed as follows
- Close the windows
- Set the ventilation system control to air flow to floor, windshield and side windows and blower control to its
highest setting.
CAUTION: Drive slowly and carefully if going through standing water (i.e. flooded roadways, etc.). Damage to the
engine could result if excess water is drawn in through the air intake system. Never drive the vehicle in water deeper
than 1 foot (300 mm).
pg. 84 Starting and driving
General information (contd)
Weight distribution affects handling
At the specified curb weight your car has a tendency to understeer, which means that the steering wheel has to be
turned more than might seem appropriate for the curvature of a bend.
This ensures good stability and reduces the risk of rear wheel skid. Remember that these properties can alter with the
vehicle load.
The heavier the load in the trunk (max. 220 lbs, 100 kg), the less the tendency to understeer.
Handling, roadholding
Vehicle load, tire design and inflation pressure all affect vehicle handling. Therefore, check that the tires are inflated to
the recommended pressure according to the vehicle load. See "Tire pressure" section.
Loads should be distributed so that capacity weight or maximum permissible axle loads are not exceeded.
Speed-sensitive power steering
(Option on certain models)
With this feature, the steering is most responsive at lower speeds to make parking, driving in city traffic, etc, easier.
The effect of the power steering diminishes as you accelerate for greater stability at highway speeds.
pg. 85 Starting and driving
Manual transmission
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Brake system
BRAKE Brake circuit malfunction
The brake system is a hydraulic system consisting of two master cylinders and two separate brake circuits. If a
problem should occur in one of these circuits, it is still possible to stop the car with the other brake circuit.
If the brake pedal must be depressed farther than normal and requires greater foot pressure, the stopping distance will
be longer.
A warning light in the instrument panel will light up to warn the driver that a fault has occurred.
If this light comes on while driving or braking, stop immediately and check the brake fluid level in the reservoir.
NOTE: Press the brake pedal hard and maintain pressure on the pedal Ð do not pump the brakes.
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.
Power brakes function only when the engine is running
The power brakes utilize vacuum pressure which is only created when the engine is running. Never let the vehicle roll
to a stop with the engine switched off.
If the power brakes are not working, the brake pedal must be pressed approximately four times harder than usual to
make up for the lack of power assistance. This can happen for example when towing your vehicle or if the engine is
switched off when the vehicle is rolling. The brake pedal feels harder than usual.
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, 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. 93 Starting and driving
Brake system (contd)
Anti-lock brakes (ABS)
If the warning lamp lights up there is a malfunction of the ABS system (the standard braking system will however
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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. The brake pedal will pulsate during braking, which is normal.
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 124
for the location of the brake fluid 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.
If the brake fluid level is above the MIN mark, drive carefully to an authorized Volvo retailer and have the brake
system inspected.
Contents | Top of Page
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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. 118 Car care
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.
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2 0 0 4
VOLVO S60
Maintenance and service
pg. 119
Volvo service 120
Working on your car122
Hood and engine compartment124
Oils and fluids125
Wiper blades129
Battery130
Bulbs133
Fuses140
pg. 120 Maintenance and service
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 Federal Clean Air Act requires vehicle manufacturers to furnish written instructions to the ultimate purchaser to
assure the proper servicing and function of the components that control emissions. These services, which are listed in
the "Warranty and Service Records Information booklet," are not covered by the warranty. You will be required to pay
for labor and material used.
Maintenance services
Your Volvo passed several major inspections before it was delivered to you, in accordance with 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 case questions arise concerning maintenance.
Inspection and service should also be performed anytime a malfunction is observed or suspected.
Page 121
provides more information about maintenance of emission-related components.
Vehicle Event Data
Your vehicle's driving and safety systems employ computers that monitor, and share with each other, information
about your vehicle's operation. One or more of these computers may store what they monitor, either during normal
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vehicle operation or in a crash or near-crash event. Stored information may be read and used by:
Volvo Car Corporation
service and repair facilities
law enforcement or government agencies
others who may assert a legal right to know, or who obtain your consent to know such information.
Applicable warranties - U.S.
In accordance with applicable U.S. and Canadian regulations, the following list of warranties is provided
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/provincial law. Refer to your
separate Warranty and Service Records Information booklet for detailed information concerning each of the warranties.
pg. 121 Maintenance and 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 system, including 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 engine and emission control systems, the timing belt and belt tensioner 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
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105,000 miles (168,000 km) and again at 150,000 miles (240,000 km).
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. 122 Maintenance and service
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!
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