2003 VOLVO S60 service

system inspected.
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.
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pg. 112 Wheels and tires
Uniform Tire Quality Grading
ALL PASSENGER CAR TIRES MUST CONFORM TO FEDERAL SAFETY REQUIREMENTS IN
ADDITION TO THESE GRADES
Quality grades can be found, where applicable, on the tire sidewall between the tread shoulder and maximum
section width. For example:
Treadwear 200 Traction AA Temperature A
TREADWEAR
The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions
on a specified government test course. For example, a tire graded 150 would wear one and one half (1 1/2) times as
well on the government course as a tire graded 100. The relative performance of tires depends upon the actual
conditions of their use, however, and many depart significantly from the norm due to variation in driving habits,
service practices and differences in road characteristics and climate.
TRACTION
The traction grades, from highest to lowest, are AA, A, B, and C, as measured under controlled conditions on specified
government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance.
WARNING!
The traction grade assigned to this tire is based on braking (straight-ahead) traction tests and is not a measure of
cornering (turning) traction.
TEMPERATURE
The temperature grades are AA (the highest), A, B, and C, representing the tire's resistance to the generation of heat
and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel.
Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive
temperature can lead to sudden tire failure. The grade C corresponds to a minimum level of performance that all
passenger car tires must meet under the Federal Motor Safety Standard No. 109. Grades B and A represent higher
levels of performance on the laboratory test wheel than the minimum required by law.
WARNING!
The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive
speed, under-inflation, or excessive loading, either separately or in combination, can cause heat buildup and possible
tire failure.
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VOLVO S60
Maintenance and service
pg. 117
Volvo service 118
Working on your car120
Hood and engine compartment122
Oils and fluids123
Wiper blades127
Battery128
Bulbs131
Fuses138
pg. 118 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 119
provides more information about maintenance of emission-related components.
Applicable warranties - U.S.
In accordance with applicable U.S. and Canadian regulations, the following list of warranties is provided
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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. 119 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 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
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. 120 Maintenance and service
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pg. 121 Maintenance and service
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. 122 Maintenance and service
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.
pg. 123 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
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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.
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. 124 Maintenance and service
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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.
pg. 125 Maintenance and service
Washer fluid reservoir
Washer fluid reservoir
The washer fluid reservoir is located in the engine compartment and holds approx. 4.7 US qts. (4.5 liters).
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