VOLVO S60 2004 Workshop Manual

With the exception of gas line antifreeze during winter months, do not add solvents, thickeners, or other store -bought
additives to your car's fuel, cooling, or lubricating systems. Overuse may damage your engine, and some of these
additives contain organically volatile chemicals. Do not needlessly expose yourself to these chemicals.
WARNING!
Never carry a cell phone that is switched on while refueling your vehicle. If the phone rings, this may cause a spark
that could ignite gasoline fumes, resulting in fire and injury.
pg. 80 Starting and driving
Fuel filler door
Press the button on the light switch panel (see illustration on page 30
) when the car is at a standstill to unlock the fuel
filler door. Please note that the fuel filler door will remain unlocked until the car begins to move forward. An audible
click will be heard when the fuel filler door relocks.
If you intend to leave your car while it is being refueled, this feature enables you to lock the doors/trunk while leaving
the fuel filler door unlocked.
You can also keep the car locked if you remain inside during refueling. The central locking button does not lock the
fuel filler door. Be sure the fuel filler door is not obstructed and is completely closed after refueling.
Open the fuel filler cap slowly during hot weather.
NOTE: During a transitional period, a small number of service stations may still have fuel nozzles that are not
compatible with the fuel filler neck on cars equipped with the evaporative control system.
Refueling
The fuel tank holds approximately:
Front wheel drive : 18.5 US gals (70 liters)
All Wheel drive : 19 US gals (72 liters)
S60R : 18 US gal. (68 liters)
with sufficient volume left over to accommodate possible expansion of the fuel in hot weather. Be aware that the
"usable" tank capacity will be somewhat less than the specified maximum. When the fuel level is low, such factors as
ambient temperature, the fuel's "Reid vapor pressure" characteristics, and terrain can affect the fuel pump's ability to
supply the engine with an adequate supply of fuel. Therefore, it is advisable to refuel as soon as possible when the
needle nears the red zone, or when the fuel warning light comes on.
CAUTION:
Do not refuel with the engine running *. Turn the ignition off or to position I. If the ignition is on, an incorrect reading
could occur in the fuel gauge
ProCarManuals.com

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
ProCarManuals.com

The engine should be idling when you move the gear selector. Never accelerate until after you feel the transmission
engage! Accelerating immediately after selecting a gear will cause harsh engagement and premature transmission wear.
Selecting P or N when idling at a standstill for prolonged periods of time will help prevent overheating of the
automatic transmission fluid.
WARNING!
Always place the gear selector in Park and apply the parking brake before leaving the vehicle. Never leave the car
unattended with the engine running.
Always open garage doors fully before starting the engine inside a garage to ensure adequate ventilation. The
exhaust gases contain carbon monoxide, which is invisible and odorless but very poisonous
Do not race a cold engine immediately after starting. Oil flow may not reach some lubrication points fast enough to
prevent engine damage.
* If two of the keys to your car are close together, e.g., on the same key ring, when you try to start the car, this could
cause interference in the immobilizer system and result in the car not starting. If this should occur, remove one of the
keys from the key ring before trying to start the car again.
pg. 82 Starting and driving
Starting the car (contd)
Ignition switch and steering wheel lock
0 - Locked position:
Remove the key to lock the steering wheel*.
WARNING!
Never turn the key to position O while driving or when the car is being towed.
I - Intermediate position** - "radio position":
Certain accessories, radio, etc. on, daytime running lights off.
II - Drive position: The key position when driving. The car's entire electrical system is connected.
III - Start position: Release the key when the engine starts. The key returns automatically to the Drive position.
A chime will sound if the key is left in the ignition and the driver's door is opened.
ProCarManuals.com

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.
ProCarManuals.com

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
ProCarManuals.com

5-speed manual transmission
Depress the clutch pedal completely when changing gears*.
Remove your foot from the clutch pedal while driving. The shift pattern should be followed.
Overdrive (5th gear) should be used as often as possible to help improve fuel economy.
* Clutch interlock
The clutch must be fully depressed before you can start your car. If the clutch is not depressed, it will not be possible
to start the engine.
6-speed manual transmission
(option on certain models)
Fifth and sixth gears should be used as often as possible to help improve fuel economy.
Engaging reverse gear
Reverse gear should only be engaged from a complete stop.
CAUTION:
ProCarManuals.com

Be careful to avoid inadvertently engaging reverse while moving forward.
pg. 86 Starting and driving
Automatic transmission (option)
Automatic transmission AW55- 50 (option)
P Park
Use this position when starting the engine or parking the car.
Never use P while the car is in motion.
The parking brake should be set whenever the car is parked.
The gear selector is mechanically locked in the P position (SHIFTLOCK). To release the gear selector from this
position, the engine must be running (or the ignition key must be in position II) and the brake pedal must be
depressed.
WARNING!
Never leave the car unattended when the engine is running. If, by mistake, the gear selector is moved from P , the car
may start moving.
R (Reverse)
Never engage R while the car is moving forward.
N (Neutral)
Neutral - no gear engaged. Use the parking brake.
D (Drive)
D is the normal driving position and should be used as often as possible to help improve fuel economy. The car should
not be moving when shifting from R to the D position.
4 (Intermediate gear)
The transmission will shift automatically between gears 4, 3, 2 or 1 from this position. The transmission cannot shift up
to ( D)rive from fourth gear.
3 (Intermediate gear)
The transmission will shift automatically between gears 3, 2 and 1 from this position. The transmission cannot shift up
to fourth gear or ( D)rive from third gear.
L (Low gears)
The transmission is locked in gears 1 and 2 when the selector is in this position.
ProCarManuals.com

NOTE: Gears 4, 3, or L can be used if you are driving in a mountainous area, towing a trailer or to increase engine
braking effect.
The transmission has a built-in limiter designed to help prevent excessive engine speeds (high rpm) when gears 4, 3 or
L are selected.
pg. 87 Starting and driving
Automatic transmission (option) (contd)
W - Winter/Wet driving mode - enhanced vehicle traction
Mode W will only function if the gear selector is in the ( D)rive position.
Press the button at the base of the gear selector to engage/disengage this driving mode (see illustration).
When the W driving mode is engaged, this is displayed in the instrument panel (see page 22).
This mode may be selected for starting/moving off on slippery roads.
NOTE: R-models are not equipped with this button.
Automatic transmission AW55- 50 - shift gate positions
The gear selector can be moved freely between N and D.
Depressing the button on the front of the gear selector knob enables you to move the gear selector to positions P, R, N,
D, 4, 3 and L.
"Kickdown"
Automatic shift to a lower gear (kickdown) is achieved by depressing the accelerator pedal fully and briskly. An
upshift will occur when approaching the top speed for a particular gear or by releasing the accelerator pedal slightly.
Kickdown can be used for maximum acceleration or when passing at highway speeds.
Automatic transmission - adaptive system
ProCarManuals.com

The automatic transmission is controlled by an adaptive control system that constantly monitors the way in which the
transmission functions. It senses and adapts each gear shift for optimal performance. The system also monitors your
particular driving style and adapts gear shifting accordingly.
Cold starts
When driving before the engine has reached its normal operating temperature, the transmission will shift up at a
slightly higher engine speeds to heat the three-way catalytic converter as quickly as possible.
pg. 88 Starting and driving
Geartronic (option)
P Park
Use this position when starting the engine or parking the car.
Never use P while the car is in motion.
The parking brake should also be set whenever the car is parked.
The gear selector is mechanically locked in the P position (SHIFTLOCK). To release the gear selector from this
position, the engine must be running (or the ignition key must be in position II) and the brake pedal must be
depressed.
WARNING!
Never leave the car unattended when the engine is running. If, by mistake, the gear selector is moved from P, the car
may start moving.
R (Reverse)
Never engage R while the car is moving forward.
N (Neutral)
Neutral - no gear engaged. Use the parking brake.
D (Drive)
D is the normal driving position and should be used as often as possible to help improve fuel economy. The car should
not be moving when shifting from R to the D position.
Automatic transmission - adaptive system
The automatic transmission is controlled by an adaptive control system that constantly monitors the way in which the
transmission functions. It senses and adapts each gear shift for optimal performance. The system also monitors your
ProCarManuals.com

particular driving style and adapts gear shifting accordingly.
Automatic transmission - shift gate positions
You can move the gear selector freely between the (MAN)ual and ( D)rive positions while driving.
Depress the button on the front of the gear selector knob to move between the R, N, D, and P positions.
pg. 89 Starting and driving
Geartronic (option) (contd)
Manual shifting - Geartronic
You can move the gear selector freely between the ( MAN)ual and ( D)rive positions while driving. Gears 3, and 4
have a "lock -up" function which reduces engine speed and helps save fuel.
The currently selected gear will be displayed in the instrument panel (see page 22
).
To access the ( MAN)ual shifting position from ( D)rive, move the gear selector to the left to MAN .
To return to the (D)rive position from MAN , move the gear selector to the right.
While driving
If you select the ( MAN)ual position while driving, the gear that was being used in the ( D)rive position will also
initially be selected in ( MAN)ual position.
Move the gear selector forward (toward "+") to shift to a higher gear or rearward (toward "-") to shift to a lower
gear.
If you hold the gear selector toward "-", the transmission will downshift one gear and will utilize the braking power
of the engine. If the current speed is too high for using a lower gear, the downshift will not occur until the speed has
decreased enough to allow the lower gear to be used.
If you slow down to a very low speed, the transmission will automatically shift down.
When starting in the ( MAN)ual position, 3rd gear is the highest gear that may be selected.
NOTE: Kickdown does not function when the transmission is in the manual shift (Geartronic) mode.The gear selector
must be in the D(Drive) position.
Kickdown
Automatic shift to a lower gear (kickdown) is achieved by depressing the accelerator pedal fully and briskly. An
upshift will occur when approaching the top speed for a particular gear or by releasing the accelerator pedal slightly.
Kickdown can be used for maximum acceleration or when passing at highway speeds.
Kickdown does not function when the transmission is in the manual shift (Geartronic) mode.
ProCarManuals.com