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VOLVO
S60

Maintenance and service

pg. 163 Maintenance and service

Volvo service 164
Maintenance Schedule 165
Working on your car 168
Hood and engine compartment 170
Oils and fluids 171
Wiper blades 175
Battery 176
Bulbs 179
Fuses 186

pg. 164 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 Clean Air Act requires vehicle manufacturers to furnish written instructions to the ultimate purchaser to assure the proper functioning of those components that control emissions. The maintenance instructions listed in this manual represent the minimum maintenance required. These services are not covered by the warranty. You will be required to pay for labor and material used. Refer to your Warranty and Service Records Information booklet for further details.

Maintenance services
Your Volvo has passed several major inspec- tions before being delivered to you, according to Volvo specifications. The maintenance services outlined in this book should be performed as indicated. The extended maintenance service intervals make it even more advisable to follow this program. Inspection and service should also be performed any time a malfunction is observed or suspected. It is recommended that receipts for vehicle emission services be retained in the event that questions arise concerning maintenance. See your Warranty and Service Records Information booklet. Applicable warranties - U. S. In accordance with U. S. Federal Regulations, the following list of applicable U. S. warranties is provided. For Canadian specification vehicles, see your separate warranty booklet.

  • 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 law. Refer to your separate Warranty and Service Records Information booklet for detailed information concerning each of the warranties.

  • pg. 165 Maintenance Schedule

    2001
    MAINTENANCE SCHEDULE
    S60

    For complete maintenance information, please refer to your
    Warranty and Service Records Information Booklet.

      R = Replace
      I = Inspect (Correct or Replace if necessary)
      L = Lubricate
    Maintenance Operation thousand miles 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 2
    (thousand km) (12) (24) (36) (48) (60) (72) (84) (96) (108) (120) (132) (144)
    EMISSION SYSTEM MAINTENANCE
    Engine oil and filter 1 R R R R R R R R R R R R
    Engine drive belt (accessory belt) I
    Air cleaner filter R R R
    Spark plugs R R R
    Automatic transmission fluid I I I I I I
    Timing belt - all engines3
    1) See section "Engine oil" for detailed information.

    NOTE: The oil should be changed at these intervals, after 750 hours of driving or after 12 months, whichever occurs first.

    2) For services beyond 90,000 miles (144,000 km), please refer to the Warranty and Service Records Information Booklet".

    3) For proper functioning of the vehicle and its emission control systems, the timing belt and tensioner must be replaced every 105,000 miles (168,000 km).

    pg. 166 Maintenance Schedule

    2001
    MAINTENANCE SCHEDULE
    S60
      R = Replace
      I = Inspect (Correct or Replace if necessary)
      L = Lubricate
    Maintenance Operation thousand miles 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90
    (thousand km) (12) (24) (36) (48) (60) (72) (84) (96) (108) (120) (132) (144)
    EMISSION SYSTEM MAINTENANCE
    Engine
    Fuel line filter1
    PCV nipple (orifice)/hoses, clean I I
    Battery (check charge and electrolyte level) I I I I I I I I I I I I
    Brakes
    Inspect brake pads, replace components as necessary I I I I I I I I I I I
    Brake fluid level2 - check I I I I I I
    Steering/suspension
    Tires3, check pressure, wear and condition I I I I I I I I I I I I
    Check power steering fluid level I I I I I I
    Body
    Power antenna (clean) L L L L L L
    Trunk/hood, hinges and latches L L L L
    Cabin air filter (see page 167 ) R R R R R R

    1) Replace at 105,000 miles (168,000 km)

    2) Brake fluid should be changed at owner request 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.).

    3) Rotate tires at owner request.

    The following items should be checked weekly by the driver (it takes only a few minutes):

    Engine oil level, brake fluid level, radiator coolant level, operation of all lights, horns, windshield wipers, tire pressure (all five tires), windshield washer fluid level

    The following should also be carried out at regular intervals:

    Washing (check all drain holes), polishing, cleaning

    pg. 167 Maintenance Schedule

    Air cleaner
    Replace the air cleaner cartridge with a new one every 30,000 miles (48,000 km). The cartridge should be replaced more often when driving under dirty and dusty conditions. The filter cannot be cleaned and therefore should always be replaced with a new one.

    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.

    Fuel filler cap, tank and lines and
    connections The effectiveness of the fuel system to contain hydrocarbons is dependent largely on a leak- free system. 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 Malfunction Indicator Lamp (" Check Engine") may indicate a fault. However, your vehicle's performance will not be affected. Use only Volvo original or approved fuel filler caps.

    Fuel (line) filter
    For proper functioning of the vehicle and its emission control systems, the fuel line 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).

    PCV system
    The orifice nipple in the intake manifold and the filter at the end of the PCV hose in the air cleaner should be inspected at 60,000 miles (96,000 km) and thereafter, at 30,000 mile (48,000 km) intervals.

    Cabin air filter
    Replace the cabin air filter with a new one at 15,000 mile (24,000 km) intervals. Volvo recommends replacing the filter more often if the car is driven under dirty and dusty condi- tions. The filter cannot be cleaned and therefore should always be replaced with a new one.

    pg. 168 Working on your car

     Working on your car

    Note the following before you begin working on your car:
    Battery

  • Ensure that the battery cables are correctly connected and tightened.
  • Never disconnect the battery when the engine is running (e. g. when replacing the battery).
  • Never use a fast charger to charge the battery. The battery cables should be disconnected when recharging.
  • The battery contains acid that is both corrosive and poisonous. It is important that the battery is handled in an environ- mentally friendly way. Let your Volvo dealer assist you.

    Hoisting the car
    If a garage jack is used to lift the car, the two jack attachments points should be used. They are specially reinforced to bear the weight of the car. A garage jack can also be placed under the front of the engine support frame. Take care not to damage the splash guard under the engine. Ensure that the jack is positioned so that the car cannot slide off it. Always use axle stands or similar structures.

    If a two- post hoist is used to lift the car, the front and rear lift arm pads should be centered under the reinforced lift plates on the inboard edge of the sill rail (see illustration).

    warningWARNING!

    The car ignition system has very high voltage!

    The voltage in the ignition system is dangerous!

    Do not touch spark plugs, ignition cables or the ignition coil when the engine is running or the ignition is switched on!

    The ignition should be switched off when:

  • Conducting engine tests.
  • Replacing parts in the ignition system, such as spark plugs, ignition coil, distributor, ignition cables, etc.
  • warningWARNING!

    Never try to repair any part of the SRS or SIPS bag systems yourself. Any interference in the system could cause malfunction and serious injury. Any work should only be performed by an authorized Volvo workshop.

  • pg. 169 Working on your car

    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.!

    warningWARNING!

    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.

    warningWARNING!

    Never remove the radiator cap while the engine is warm. Wait until the car cools.

    pg. 170 Hood and engine compartment

     Hood and engine compartment

    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.

    warningWARNING!

    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

     Hood and engine compartment

    warningWARNING!

    The cooling fan (6) may start or continue to operate (for up to 6 minutes) after the engine has been switched off.

  • pg. 171 Oils and fluids

    Oil quality
    Meeting minimum ILSAC specification GF- 2, including ACEA A1, API SJ, SJ/ CF and SJ/ Energy Conserving. Your Volvo has been certified using ILSAC oil specification GF- 2 5W/ 30.

    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. Volvo does not recommend the use of oil additives.

    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.

    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 at right.

     Oils

    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 at right.

    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.

     Oils
  • The API Service Symbol "donut" is divided into three parts:
  • The top half describes the oil's perfor- mance 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. 172 Oils and fluids

    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.

    warningWARNING!

    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.

     oil
  • pg. 173 Oils and fluids

     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).

    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).


    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!

    warningWARNING!

    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. 174 Oils and fluids

    clutch and brake reservoir

    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+

    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

    Power steering fluid reservoir
    The fluid level should always be between the MIN and MAX marks.

    Fluid type: ATF

    Replace: No fluid change required



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