2004 VOLVO S60 service

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.
WARNING!
CALIFORNIA Proposition 65 Warning!
Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the
state of California to cause cancer, and birth defects or other reproductive harm. In addition, certain fluids contained
in vehicles and certain products of component wear contain or emit chemicals known to the State of California to
cause cancer, and birth defects or other reproductive harm.
WARNING!
If your vehicle is involved in an accident, unseen damage may affect your vehicle's driveability and safety.
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.
For Volvo, all homogeneous plastic parts weighing more than 1.7 oz. (50 grams) are marked with international
symbols that indicate how the component is to be sorted for recycling.
In addition to continuous environmental refinement of conventional gasoline-powered internal combustion engines,
Volvo is actively looking at advanced technology alternative-fuel vehicles.
When you drive a Volvo, you become our partner in the work to lessen the car's impact on the environment.
To reduce your vehicle's environmental impact, you can:
Maintain proper air pressure in your tires. Tests have shown decreased fuel economy with improperly inflated tires.
Follow the recommended maintenance schedule in your Warranty and Service Records Information booklet.
Drive at a constant speed.
See an authorized Volvo retailer as soon as possible for inspection if the check engine (malfunction indicator) lamp
illuminates, or stays on after the vehicle has started.
Properly dispose of any vehicle-related waste such as used motor oil, used batteries, brake pads, etc.
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Instruments and controls
Climate control
Interior
Locks and alarm
Starting and driving
Wheels and tires
Car care
Maintenance and service
Specifications
Audio
Index
Back Cover
Contents | Top of Page
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WARNING!
Never drive an SRS equipped car with your hands on the steering wheel pad / airbag housing.
Passenger side airbag
The airbag on the front passenger side is folded up in a compartment above the glove compartment. The panel is
embossed SRS.
WARNING!
No objects, accessory equipment or stickers may be placed on, attached to, or installed near the SRS cover in the
center of the steering wheel, the SRS cover above the glove compartment or the area affected by airbag deployment.
Passenger side airbag - location
WARNING!
As its name implies, SRS is designed to be a SUPPLEMENT to - not a replacement for - the three-point belt system.
For maximum protection, wear seat belts at all times. Be aware that no system can prevent all possible injuries that
may occur in an accident.
When installing any optional equipment, make sure that the SRS system is not damaged. Do not attempt to service
any component of the SRS yourself. Attempting to do so may result in serious personal injury. If a problem arises,
take your car to the nearest authorized Volvo retailer for inspection as soon as possible.
pg. 5 Safety
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Children must never be allowed in the front passenger's seat. Volvo recommends that ALL occupants (adults and
children) shorter than 4 feet 7 inches (140 cm) be seated in the back seat of any vehicle with a front passenger -side
airbag. See page 19
for guidelines.
Occupants in the front passenger's seat must never sit on the edge of the seat, sit leaning toward the instrument panel
or otherwise sit out of position. The occupant's back must be as upright as comfort allows and be against the seat
back with the seat belt properly fastened.
Feet must be on the floor, e.g. not on the dash, seat or out of the window.
No objects or accessory equipment, e.g. dash covers, may be placed on, attached to, or installed near the SRS hatch
(the area above the glove compartment) or the area affected by airbag deployment (see illustration on page 4
).
There should be no loose articles, e.g. coffee cups, on the floor, seat or dash area.
Never try to open the SRS cover on the steering wheel or the passenger side dash. This should only be done by an
authorized Volvo service technician.
Failure to follow these instructions can result in injury to the vehicle occupants
Warning light in the instrument panel
A self -diagnostic system incorporated in the sensor monitors the SRS. This system does not, however, monitor the
Side Impact Protection System (SIPS) airbags. If a fault is detected, the warning light will illuminate. The light is
included in the warning/indicator light cluster in the instrument panel. Normally, the SRS warning lamp should light
up when the ignition key is turned to positions I, II or III and should go out after 7 seconds or when the engine is
started. Check that this light is functioning properly every time the car is started.
The following items are monitored by the self -diagnostic system:
Sensor unit
Cable harness
Gas generator
WARNING!
If the SRS warning light stays on after the engine has started or if it comes on while you are driving, drive the car to
the nearest authorized Volvo retailer for inspection as soon as possible.
pg. 7 Safety
NOTE: The information on this page does not pertain to the Side Impact Protection System airbags.
When are the airbags deployed?
The SRS system is designed to deploy during certain frontal or front -angular collisions, impacts, or decelerations,
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depending on the crash severity, angle, speed and object impacted. The SRS sensor is designed to react to both the
impact of the collision and the inertial forces generated by it and to determine if the intensity of the collision is
sufficient for the seat belt tensioners or airbags to be deployed.
If the airbags have been deployed, we recommend the following:
Have the car towed to an authorized Volvo retailer. Never drive with the airbags deployed.
Have an authorized Volvo retailer replace the SRS system components.
Use only new, Genuine Volvo Parts when replacing SRS components (airbags, seat belts, tensioners, etc.).
When are the airbags NOT deployed?
Not all frontal collisions activate the SRS system. If the collision involves a nonrigid object (e.g., a snow drift or
bush), or a rigid, fixed object at a low speed, the SRS system will not necessarily deploy. Front airbags do not
normally deploy in a side impact collision, in a collision from the rear or in a rollover situation. The amount of
damage to the bodywork does not reliably indicate if the airbags should have deployed or not.
Seat belts - the heart of the Volvo safety system
The heart of the Volvo safety system is the three-point seat belt (a Volvo invention)! In order for the SRS system to
provide the protection intended, seat belts must be worn at all times by everyone in the car. The SRS system is a
supplement to the seat belts.
WARNING!
Never drive with the airbags deployed. The fact that they hang out can impair the steering of your car. Other safety
systems can also be damaged. The smoke and dust formed when the airbags are deployed can cause skin and eye
irritation in the event of prolonged exposure.
pg. 8 Safety
Airbags (Supplemental Restraint System) (Contd)
WARNING!
If your car has been subjected to flood conditions (e.g. soaked carpeting/standing water on the floor of the vehicle)
or if your car has become flood-damaged in any way, do not attempt to start the vehicle or put the key in the ignition
before disconnecting the battery (see below). This may cause airbag deployment which could result in personal
injury. Have the car towed to an authorized Volvo retailer for repairs.
Automatic transmission:
Before attempting to tow the car, use the following procedure to override the shiftlock system to move the gear
selector to the neutral position.
Switch off the ignition for at least 10 minutes and disconnect the battery
Wait at least one minute
Insert the key in the ignition and turn it to position II
Press firmly on the brake pedal.
Move the gear selector from ( P)ark to the ( N)eutral position.
There is no maintenance to perform on the SRS yourself. The month and year shown on the decal on the door pillar
indicate when you should contact your Volvo retailer for specific servicing or replacement of airbags and seat belt
tensioners. This service must be performed by an authorized Volvo retailer.
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No objects, accessory equipment or stickers may be placed on, attached to or installed near, the SIPS airbag system
or in the area affected by SIPS airbag deployment (see illustration above).
Never try to open or repair any components of the SIPS airbag system. This should be done only by an authorized
Volvo service technician.
In order for the SIPS airbag to provide its best protection, both front seat occupants should sit in an upright position
with the seat belt properly fastened.
Failure to follow these instructions can result in injury to the occupants of the vehicle in the event of an accident.
pg. 11 Safety
The SIPS airbag system
This system consists of a gas generator (1), the side airbags (2), and electronic sensors/cables (3).
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Warning symbol in center of dashboard
This symbol shines as a red or yellow light depending on the severity of the discovered fault.
Red symbol - Stop the car as soon as possible in a suitable location and read the message shown in the text window.
Yellow symbol - Follow the instructions shown in the text window.
Anti-lock brake system ABS
If the warning light comes on, there is a malfunction of the ABS system (the standard braking system will still
function). The vehicle should be driven to a Volvo retailer for inspection. See page 93
for additional information.
Stability Traction Control (STC)* system or Dynamic Stability Traction Control (DSTC) system**
This indicator light will flash when STC or DSTC is actively working to stabilize the car. See page 94
for more
detailed information.
BRAKE Brake failure warning light
If the light comes on while driving or braking, stop immediately, open the hood and check the brake fluid level in the
reservoir. See page 124
for reservoir position and page 127 for instructions.
Canadian models are equipped with this warning light:
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).
* Standard on all models except the T5 turbo.
** Standard on the T5 turbo, option on all other models.
pg. 24 Instruments and controls
Indicator and warning symbols (Contd)
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 an authorized Volvo retailer and have the brake system
inspected.
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Indicator and warning symbols (Contd)
Messages in the text window
When a warning light in the instrument panel comes on, a message is also displayed in the text window. After you
have read the message, you can erase it by pressing button A (see illustration).
NOTE: Certain messages cannot be erased until the condition has been corrected.
If a warning message is displayed when e.g. you are using the trip computer this message must be erased before you
can access the function of your choice. Press button A to erase the warning message.
You can scroll through the stored messages by pressing button A (see illustration). The text window can be cleared
(the message will be returned to memory) by pressing button A again.
MessageMeaning:
STOP
SAFELY: Stop and switch off the engine - to help prevent serious risk of damage.
STOP
ENGINE: Stop and switch off the engine - to help prevent serious risk of damage.
SERVICE
URGENT: Take your car to an authorized Volvo retailer for inspection as soon as possible.
SEE
MANUAL: Refer to your owner's manual. For additional information, please contact your Volvo retailer.
SERVICE
REQUIRED: Take your car to an authorized Volvo retailer for inspection at your convenience (but preferably before
the next scheduled maintenance service).
FIX NEXT
SERVICE: Have the system affected inspected at the next scheduled maintenance service.
TIME FOR
REGULAR
SERVICE: This light will come on at 7,500 mile (12,000 km) intervals, after 750 hours of driving or after 12
months, whichever occurs first, to remind the driver that the service interval has been exceeded. The
light will stay on for 2 minutes after start until reset by the servicing retailer.
1) OIL
LEVEL LOW
- FILL OIL* Check the oil level and top up if necessary. See page 125
2) OIL
LEVEL LOW
- STOP
SAFELY*Stop as soon as possible and switch off the engine, check the oil level and top up if necessary. See
page 125
2) OIL
LEVEL LOW
- STOP
ENGINE*Stop as soon as possible and switch off the engine, check the oil level and top up if necessary. See
page 125
2) OIL
LEVEL LOW
Stop as soon as possible and switch off the engine, check the oil level and top up if necessary. See
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