engine VOLVO S60 2005 Service Manual
[x] Cancel search | Manufacturer: VOLVO, Model Year: 2005, Model line: S60, Model: VOLVO S60 2005Pages: 120, PDF Size: 2.27 MB
Page 88 of 120
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. 141 Maintenance and service
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 to standards using ILSAC oil specification GF-2 5W -30. 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.
Volvo Cars recommends Castrol.
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 above.
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.
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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. 142 Maintenance and service
Oils and fluids (Contd)
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.
R-models
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R-models are equipped with an oil level warning system. If the engine oil level becomes too low, the warning light in
the instrument panel will come on and a warning will be displayed in the text window.
If the yellow warning light in the instrument panel comes on and the text OIL LEVEL LOW/ FILL OIL is displayed,
stop safely as soon as possible and add 1 qt (1 liter) of oil. Check the oil level with the dipstick before restarting the
engine.
If the red warning light in the instrument panel comes on and the text OIL LEVEL LOW/STOP SAFELY-->STOP
ENGINE-->SEE MANUAL is displayed, stop safely as soon as possible and add oil (not more than 1.6 qts (1.5 liters).
Check the oil level with the dipstick before restarting the engine. If no oil level is visible on the dipstick, do not start
the engine. Have the car towed to an authorized Volvo workshop.
pg. 143 Maintenance and service
Washer fluid reservoir
Washer fluid reservoir
The washer fluid reservoir is located in the engine compartment and holds approx. 6.8 US qts (6.4 liters) or 4.8 US qts
(4.5 liters) on the S60 R.
During cold weather, the reservoir should be filled with windshield washer solvent containing antifreeze.
Coolant reservoir
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).
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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. 144 Maintenance and service
Oils and fluids (Contd)
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 ADD and FULL marks.
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2 0 0 5
VOLVO S60
Specifications
pg. 161 Specifications
Label information 162
Dimensions and weights163
Capacities165
Lubricants166
Cooling system166
Three way catalytic converter167
Suspension168
Bulbs169
Electrical system170
Engine specifications171
All specifications are subject to change without prior notice.
pg. 162 Specifications
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): Canadian models only.
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
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Capacities
Fuel tankFront wheel drive, non-turbo models - 18.5 US gal. (70 liters)
All turbo models - 18 US gal. (68 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)
B5254T2 6.1 US qts. (5.8 liters)
B5254T4 5.5 US qts (5.2 liters)
Transmission oil
Manual (M 56) 2.2 US qts. (2.1 liters)
Manual (M 66) 2.1 US qts. (2.0 liters)
Automatic (AW 55-50) 7.6 US qts. (7.2 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
Windshield washer reservoir 6.8 US qts (6.4 liters)
S60 R 4.8 US qts (4.5 liters)
Minimum octane requirement - AKI 87 (RON 91) unleaded fuel (See also page 84
)
pg. 166 Specifications
Lubricants
Engine oil
Meeting minimum ILSAC specification GF-2, including ACEA A1, API SJ, SJ/ CF and SJ/Energy Conserving.
Oil additives must not be used.
Transmission
Oil grade:
Manual: MTF 97309
Automatic: JWS 3309
Different types of oil should never be mixed.
Power steering
Grade: Volvo synthetic power steering fluid (Pentosin CHF 11S) P/N 1161529 or equivalent.
Brake fluid
Fluid type: DOT 4+ boiling point > 536°F (280° C)
Cooling system
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TypePositive pressure, closed system.
CoolantVolvo 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. 167 Specifications
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.
pg. 168 Specifications
Suspension
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. 169 Specifications
Bulbs
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Page 99 of 120
BulbsTypeSocket
1. High beam H9 65W
2. Low beam H11 55W
3. Bi -Xenon headlight (option) D2R 35W
4. Front foglights H1 55
4. Front foglights (S60 R) H3 55W
5. Front parking lights, front side marker lights, rear footwell lighting, license plate lighting W5WW2.1x9.5d
6. Front/rear turn signals (amber) PY21WBAU15s
7. Side turn signals WY5WW2.1x9.5d
8. Brake lights, backup lights, rear foglight P21WBA15s
9. Rear parking light P21/4WBAZ15d
10. Rear parking light R5WBA15s
10. Rear side marker light R10WBA15s
11. License plate lighting WW5SV8.5
11. Front footwell lighting, cargo area lighting C5WSV8.5
12. Vanity mirror 1.2WSV5.5
WARNING!
Bi -Xenon headlights (option) - due to the high voltage used by these headlights, these bulbs should only be replaced
by an authorized Volvo service technician.
pg. 170 Specifications
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
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Page 100 of 120
Starter motor, power1.4 kW
Spark plugsP/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:
-Replacing distributor ignition components e.g. plugs, coil, etc.
-Do not touch any part of the distributor ignition system while the engine is running. This may result in unintended
movements and body injury.
pg. 171 Specifications
Engine specifications
B5244S B5244T5B5254T2 B5254T4
Output (kW/rps) 123/100191/92154/83 220/92*
(hp/rpm) 165/6000257/5500208/5000 300/5500*
Torque (Nm/rps) 225/75330/42-87320/25-75 400/31-95**
(ft. lbs./rpm) 166/4500258/2100-5000236/1500-4500 295/1950-5250**
No. of cylinders 555 5
Bore (in/mm) 3.27/833.19/813.19/81 3.27/83
Stroke (in/mm) 3.54/903.67/93.23.67/93.2 3.67/93.2
Cylinder displacement,1 2.44 (148.6 cu. in.)2.4 (146.5 cu. in.)2.52 (153.8 cu. in.) 2.52 (153.8 cu. in.)
Compression ratio 10.3:18.5:19.0:1 8.5:1
Charge air cooler (Intercooler)
Turbocharged engines employ a turbo-compressor 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.
* Automatic transmission: 220 kW at 100 rps, 300 hp at 6000 rpm
** Automatic transmission: 350Nm at 32-100 rps, 258 ft. lbs at 1850-6000 rpm
pg. 172 Specifications
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.
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