2002 VOLVO S60 fuel cap

wheel torque automatic transmission fluid airbag headlight aiming overheating AUX

Page 2 of 106

VOLVO S60 2002 Owners Manual 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

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.
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Page 56 of 106

VOLVO S60 2002 Owners Manual Fuel filler door
Press the button on the light switch panel (see illustration on page 40) when the car is at a standstill to unlock the fuel
filler door. Please note that the fuel filler door will

Fuel filler door
Press the button on the light switch panel (see illustration on page 40) 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 is driven again at a speed of over
approximately 5 mph (8km/h). 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 is designed to hold approximately 18.5 US gals (70 liters) or 21.1 US gals (80 liters) on turbo models,
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 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
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Page 57 of 106

VOLVO S60 2002 Owners Manual Volvo original or approved fuel filler caps.
pg. 131 Starting the car
Starting the engine
1. Fasten the seat belt.
WARNING!
Before starting, check that the seat, steering wheel and mirrors are adju

Volvo original or approved fuel filler caps.
pg. 131 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 102, 104.
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.
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
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. 132 Starting the car
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Page 59 of 106

VOLVO S60 2002 Owners Manual 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

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:
Worn or dirty spark plugs
Incorrect spark plug gap
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.
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).
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.
pg. 134 General information
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.
pg. 135 Manual transmission
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Page 80 of 106

VOLVO S60 2002 Owners Manual Parts and Accessories Limited Warranty
Corrosion Protection Limited Warranty
Seat Belt and Supplemental Restraint Systems Limited Warranty
Emission Design and Defect Warranty
Emission Performa

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
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Page 83 of 106

VOLVO S60 2002 Owners Manual 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. Radia

Page 88 of 106

VOLVO S60 2002 Owners Manual 2 0 0 2
VOLVO S60
Specifications
pg. 193 Specifications
Label information 194
Dimensions, weights195
Capacities197
Lubricants,198
Cooling system198
Three way catalytic converter199
Suspension200
Bulb

Page 91 of 106

VOLVO S60 2002 Owners Manual 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

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